ENGINE ASSEMBLY REMOVAL


  1. DISCHARGE FUEL SYSTEM PRESSURE


    1. Discharge the fuel system pressure Click here.

  2. REMOVE BATTERY


    1. A0137MN

      Disconnect the negative battery cable.

    2. Disconnect the positive battery cable.

    3. Remove the bolt, clamp, and battery.

    4. A0136RYE03

      Remove the 4 bolts, clamp, and battery carrier.

      Tech Tips

      Remove the A bolt from the service hole on the battery carrier.

  3. REMOVE FRONT WIPER ARM HEAD CAP


    1. Remove the front wiper arm head cap Click here.

  4. REMOVE FRONT WIPER ARM LH


    1. Remove the front wiper arm LH Click here.

  5. REMOVE HOOD TO COWL TOP SEAL


    1. Remove the hood to cowl top seal Click here.

  6. REMOVE COWL TOP VENTILATOR LOUVER RH


    1. Remove the cowl top ventilator louver RH Click here.

  7. REMOVE COWL TOP VENTILATOR LOUVER LH


    1. Remove the cowl top ventilator louver LH Click here.

  8. REMOVE FRONT WIPER MOTOR & LINK ASSEMBLY


    1. Remove the front wiper motor & link assembly Click here.

  9. REMOVE COWL TOP PANEL OUTER


    1. A0138B1

      Remove the 10 bolts and cowl top panel outer.

  10. DISCONNECT ENGINE WIRE


    1. A0137O3

      Disconnect the engine wire harness connectors from the engine room relay block.

    2. Remove the bolt and engine room relay block.

    3. A0136V7

      Disconnect the engine wire harness connectors from the ECM.

    4. Disconnect the engine wire harness clamp.

    5. Remove the 3 bolts and ECM.

    6. A0138EF

      Remove the 2 bolts, then disconnect the 2 ground terminals.

    7. A0136MC

      Remove the nut, then disconnect the battery terminal B.

  11. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A013637

      Disengage the air cleaner cap sub-assembly clamp.

    2. Loosen the hose clamp, then remove the air cleaner cap sub-assembly.

    3. Remove the air cleaner filter element from the air cleaner case.

    4. A0138BV

      Disconnect the throttle control cable from the throttle body.

  12. REMOVE FUEL VAPOR FEED HOSE NO.1 AND NO.2


    1. A0137U4

      Disconnect the fuel vapor feed hoses No.1 and No.2.

    2. Disconnect the VSV connector.

  13. REMOVE ENGINE UNDER COVER


    1. A013649

      Remove the 9 bolts.

    2. Remove the 5 screws and engine under cover.

  14. REMOVE FRONT BUMPER COVER


    1. Remove the front bumper cover Click here.

  15. REMOVE FAN & GENERATOR V BELT


    1. Remove the fan and generator V belt Click here.

  16. DRAIN ENGINE COOLANT


    1. Drain the engine coolant Click here.

  17. REMOVE FRONT EXHAUST PIPE ASSEMBLY


    1. Remove the front exhaust pipe assembly Click here.

  18. REMOVE RADIATOR HOSE INLET

  19. REMOVE RADIATOR HOSE OUTLET

  20. REMOVE FRONT CROSS MEMBER SUB-ASSEMBLY


    1. Remove the front cross member sub-assembly Click here.

  21. REMOVE RADIATOR ASSEMBLY


    1. Remove the radiator assembly Click here.

  22. REMOVE W/ MOTOR FAN ASSEMBLY


    1. Remove the w/ motor fan assembly Click here.

  23. SEPARATE W/ PULLEY COMPRESSOR ASSEMBLY (W/ AIR CONDITIONER)

    Tech Tips

    Move the compressor and A/C hoses to the side of the engine to prevent them from interfering with other parts in the following procedure.


    1. Separate the w/ pulley compressor assembly (w/ air conditioner) Click here.

  24. DISCONNECT VACUUM HOSE ASSEMBLY


    1. A01385Q

      Pinch the retainer as illustrated, then pull out the vacuum hose connector from the pipe.

  25. DISCONNECT HEATER WATER HOSE INLET A


    1. A01372J

      Using pliers, grip the claws of the clip and slide the clip to disconnect the heater water inlet hose A.

  26. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)

    Tech Tips

    Disconnection procedure for the heater water outlet hose A is the same as for the heater water inlet hose A.

  27. REMOVE FUEL TUBE SUB-ASSEMBLY


    1. A0137P0

      Remove the fuel pipe clamp.

    2. A0136A2

      Pinch the retainer as illustrated, then pull out the fuel tube connector from the pipe.

      Note


      • Remove any dirt and foreign objects on the fuel tube connector before performing this work.

      • Do not allow any scratches or foreign objects on the O-rings of the fuel tube connector, otherwise the pipe may not be sealed properly.

      • Perform this work by hand. Do not use any tools.

      • Do not forcibly bend, twist, or turn the nylon tube.

      • Protect the disconnected part by covering it with a vinyl bag after disconnecting the fuel tube.

      • If the fuel tube connector and pipe are stuck, separate them by pushing and pulling on the connection.

  28. SEPARATE TRANSAXLE CONTROL CABLE ASSEMBLY


    1. Separate the transaxle control cable assembly Click here.

  29. SEPARATE CLUTCH RELEASE CABLE ASSEMBLY


    1. Separate the clutch release cable assembly Click here.

  30. PLACE FRONT WHEELS FACING STRAIGHT A HEAD

  31. REMOVE STEERING COLUMN HOLE COVER PLATE


    1. Remove the steering column hole cover plate Click here.

  32. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY NO.2


    1. Separate the steering intermediate shaft assembly No.2 Click here.

  33. DRAIN MANUAL TRANSAXLE OIL


    1. Drain the manual transaxle oil Click here.

  34. REMOVE FRONT WHEELS

  35. REMOVE FRONT AXLE HUB NUT RH


    1. Remove the front axle hub nut RH Click here.

  36. REMOVE FRONT AXLE HUB NUT LH


    1. Remove the front axle hub nut LH Click here.

  37. SEPARATE TIE ROD END SUB-ASSEMBLY RH

    SST
    09611-12010

    1. Separate the tie rod end sub-assembly RH Click here.

  38. SEPARATE TIE ROD END SUB-ASSEMBLY LH

    SST
    09611-12010

    1. Separate the tie rod end sub-assembly LH Click here.

  39. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER RH

    SST
    09628-00011

    1. Separate the front suspension arm sub-assembly lower RH Click here.

  40. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER LH

    SST
    09628-00011

    1. Separate the front suspension arm sub-assembly lower LH Click here.

  41. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

    SST
    09930-00010

    1. Remove the front drive shaft assembly RH Click here.

  42. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

    SST
    09930-00010

    1. Remove the front drive shaft assembly LH Click here.

  43. REMOVE ENGINE ASSEMBLY W/ TRANSAXLE


    1. Set the engine lifter.

    2. A0137YC

      Remove the 4 bolts from the engine mounting insulator RH.

    3. A0138YS

      Remove the nut and engine mounting insulator RH.

    4. A01371N

      Remove the 4 bolts from the engine mounting insulator LH.

    5. A0138HJ

      Remove the 3 bolts and engine mounting insulator LH.

    6. A01388M

      Remove the 6 bolts.

    7. A0136Z3

      Remove the engine assembly with transaxle.

    8. A0138UYE02

      Install the engine hanger (12281-40030) with the bolt (91671-80820).

      Torque:
      28 N*m  { 285 kgf*cm, 21 ft.*lbf }

      Tech Tips


      • Securely install the front engine hanger (12281-40030) to the engine assembly.

      • Be sure to hold down on the stopper when installing the engine hanger.

    9. Install the engine hanger No.2 (12282-40010) with the bolt (91671-80820).

      Torque:
      28 N*m  { 285 kgf*cm, 21 ft.*lbf }

      Tech Tips


      • Securely install the front engine hanger No.2 (12282-40010) to the engine assembly.

      • Be sure to hold down on the stopper when installing the engine hanger.

    10. Attach the engine sling and hang the engine with the chain block.

  44. SEPARATE FRONT SUSPENSION CROSS MEMBER SUB-ASSEMBLY


    1. A01389H

      Remove the bolt, then separate the engine assembly with transaxle from the front suspension cross member assembly.

  45. REMOVE STARTER ASSEMBLY


    1. Remove the starter assembly Click here, Click here.

  46. REMOVE MANUAL TRANSAXLE ASSEMBLY


    1. Remove the manual transaxle assembly Click here.

  47. REMOVE CLUTCH COVER ASSEMBLY


    1. Remove the clutch cover assembly Click here.

  48. REMOVE CLUTCH DISC ASSEMBLY


    1. Remove the clutch disc assembly Click here.

  49. REMOVE FLYWHEEL SUB-ASSEMBLY


    1. A0137XIE02

      Hold the crankshaft with SST.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
    2. A0138G0

      Remove the 6 bolts and flywheel sub-assembly.

  50. REMOVE IGNITION COIL NO.1


    1. A0138SF

      Disconnect the 3 connectors.

    2. Remove the 3 bolts and 3 ignition coils.

  51. REMOVE SPARK PLUG


    1. A0137PG

      Remove the 3 spark plugs.

  52. REMOVE GENERATOR ASSEMBLY


    1. Remove the generator assembly Click here.

  53. REMOVE FAN BELT ADJUSTING BAR


    1. Remove the fan belt adjusting bar Click here.

  54. REMOVE EXHAUST MANIFOLD


    1. A0137U7

      Disconnect the oxygen sensor connector.

    2. Remove the 3 bolts, 2 nuts, and exhaust manifold.

    3. Remove the exhaust manifold gasket.

  55. REMOVE COMPRESSOR MOUNTING BRACKET NO.1 (W/ AIR CONDITIONER)


    1. A0137BB

      Remove the 2 bolts and compressor mounting bracket.

  56. REMOVE WATER BY-PASS PIPE NO.1


    1. A0137YT

      Remove the bolt and 2 nuts.

    2. Remove the bolt and clamp, then remove the water by-pass pipe No.1.

    3. Remove the clamp, then remove the water by-pass hose from the water by-pass pipe No.1.

    4. Remove the water by-pass pipe gasket.

  57. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY

  58. REMOVE OIL LEVEL GAUGE GUIDE


    1. A0137FF

      Disconnect the 2 clamps from the oil level gauge guide.

    2. Remove the bolt and oil level gauge guide.

    3. A0138AI

      Remove the O-ring from the oil level gauge guide.

  59. REMOVE OIL LEVEL GAUGE GUIDE SUPPORT


    1. A0136CW

      Remove the oil level gauge guide support.

  60. REMOVE THROTTLE BODY ASSEMBLY


    1. A0137MK

      Disconnect the throttle body assembly connector.

    2. Remove the 3 bolts and throttle body assembly.

    3. Remove the throttle body gasket from the intake manifold.

  61. REMOVE FUEL DELIVERY PIPE


    1. Remove the fuel delivery pipe Click here.

  62. REMOVE FUEL INJECTOR


    1. Remove the fuel injector Click here.

  63. REMOVE VACUUM SENSOR


    1. A01383I

      Disconnect the vacuum sensor connector.

    2. Remove the 2 bolts and vacuum sensor.

  64. REMOVE INTAKE MANIFOLD


    1. A0138RJ

      Disconnect the PCV hose.

    2. Remove the 4 bolts, 2 nuts, and intake manifold.

    3. Remove the intake manifold gasket from the intake manifold.

  65. REMOVE THERMOSTAT


    1. A0138C2

      Remove the 2 bolts, inlet water, and thermostat.

    2. Remove the thermostat gasket from the thermostat.

  66. REMOVE CRANKSHAFT POSITION SENSOR


    1. A0137QZ

      Disconnect the crankshaft position sensor connector.

    2. Remove the bolt and crankshaft position sensor.

  67. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A01379D

      Disconnect the camshaft timing oil control valve assembly connector.

    2. Remove the bolt and camshaft timing oil control valve assembly.

  68. REMOVE OIL CONTROL VALVE FILTER


    1. A01369E

      Using the hexagon wrench, remove the oil control valve filter.

    2. Remove the oil control valve filter gasket.

  69. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A013746

      Disconnect the engine oil pressure switch assembly connector.

    2. Remove the engine oil pressure switch assembly.

  70. REMOVE KNOCK CONTROL SENSOR


    1. A0136FS

      Disconnect the knock control sensor connector.

    2. Remove the bolt and knock control sensor.

  71. REMOVE CAMSHAFT POSITION SENSOR


    1. A0138M3

      Disconnect the camshaft position sensor connector.

    2. Remove the bolt and camshaft position sensor.

  72. REMOVE E.F.I. ENGINE COOLANT TEMPERATURE SENSOR


    1. A013793E01

      Disconnect the E.F.I. engine coolant temperature sensor connector.

    2. Using SST, remove the E.F.I. engine coolant temperature sensor and gasket.

      SST
      09817-33190

      Note

      Do not use parts that have been dropped or received strong impact.