ENGINE ASSEMBLY REMOVAL


  1. PRECAUTION

    Note

    After turning the ignition switch off, waiting time may be required before disconnecting the cable from the battery terminal. Therefore, make sure to read the disconnecting the cable from the battery terminal notice before proceeding with work Click here.

  2. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  3. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

  4. REMOVE FRONT WIPER MOTOR AND LINK ASSEMBLY

    Click here

  5. REMOVE FRONT AIR SHUTTER SEAL RH

    A013795

    1. Remove the 2 clips and front air shutter seal RH.

  6. REMOVE FRONT NO. 1 VENTILATOR SEAL

    A0137ZX

    1. Remove the 2 clips and No. 1 front ventilator seal.

  7. REMOVE COWL TOP PANEL OUTER

    A01392T

    1. Disengage the wire harness clamp.

    2. Disengage the grommet and separate the wire harness.

    3. A0137JB

      Remove the 10 bolts and cowl top panel outer.

  8. REMOVE BATTERY


    1. Loosen the nut and disconnect the battery positive (+) terminal.

    2. A0136L6

      Remove the bolt and the battery clamp.

    3. Remove the battery.

  9. SEPARATE ENGINE ROOM RELAY BLOCK


    1. Remove the engine room relay block cover.

    2. A0136ZN

      Disconnect the 3 connectors from the engine room relay block.

    3. Disengage the 2 claws and separate the wire harness.

    4. Remove the 2 bolts.

    5. Disengage the 4 wire harness clamps and separate the engine room relay block.

  10. REMOVE BATTERY CLAMP SUB-ASSEMBLY


    1. A0135TU

      Remove the 3 bolts and the battery clamp sub-assembly.

  11. DISCONNECT ENGINE WIRE

    A0136UY

    1. Disengage the wire harness clamp.

    2. Remove the bolt and disconnect the ground wire from the transaxle.

    3. A0136YN

      Remove the 2 bolts and disconnect the 2 ground wires.

    4. Disengage the wire harness clamp.

    5. Slide the levers to disengage the locks, and separate the 2 connectors from the ECM.

      Text in Illustration
      A013859 Slide
    6. A0136MC

      Remove the nut and disconnect the battery terminal B.

  12. REMOVE AIR CLEANER CAP SUB-ASSEMBLY


    1. A0137CCE01

      Remove the 4 clamps.

    2. Remove the 2 clamps, then remove the air cleaner cap and air cleaner filter element.

  13. SEPARATE ACCELERATOR CONTROL CABLE ASSEMBLY


    1. A0136PK

      Loosen the nut shown in the illustration, and then disconnect the accelerator control cable.

  14. REMOVE NO. 1 FUEL VAPOR FEED HOSE


    1. A0137IH

      Loosen the hose clip and disconnect the No. 1 fuel vapor feed hose.

  15. REMOVE NO. 2 FUEL VAPOR FEED HOSE


    1. A0137N0

      Loosen the hose clip and disconnect the No. 2 fuel vapor feed hose.

  16. REMOVE FRONT BUMPER COVER

    Click here

  17. REMOVE FAN AND GENERATOR V BELT


    1. A0138MFE01
      Text in Illustration
      *a No Measurable Clearance

      Loosen the A bolt.

    2. Loosen the B bolt.

    3. Loosely tighten the B bolt until there is no measurable clearance.

    4. Loosen the C bolt.

    5. Remove the fan and generator V belt.

  18. DRAIN ENGINE COOLANT

    Note

    To avoid the danger of being burned, do not remove the radiator cap sub-assembly while the engine and radiator assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.


    1. A0137DX

      Loosen the cylinder block drain cock plug, then drain the engine coolant.

      Tech Tips

      The cylinder block drain cock plug is positioned on the bottom edge of the timing chain or belt cover sub-assembly.

    2. Remove the radiator cap sub-assembly.

      A0138A2E03

    3. Disconnect the radiator outlet hose from the engine side, then drain the engine coolant by bending the hose.

  19. REMOVE FRONT EXHAUST PIPE ASSEMBLY

    Click here

  20. REMOVE INLET RADIATOR HOSE

  21. REMOVE OUTLET RADIATOR HOSE

  22. REMOVE RADIATOR ASSEMBLY

    Click here

  23. SEPARATE COMPRESSOR WITH PULLEY ASSEMBLY (w/ Air Conditioning System)

    Tech Tips

    It is not necessary to completely remove the compressor. With the hoses connected to the compressor, hang the compressor on the vehicle body with a rope.


    1. A013767E03
      Text in Illustration
      *1 No. 1 Compressor Stay

      Disconnect the connector.

    2. Remove the bolt, nut and No. 1 compressor stay.

    3. Remove the 3 bolts and separate the compressor with pulley assembly.

  24. DISCONNECT VACUUM HOSE ASSEMBLY


    1. A01377N

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

      Text in Illustration
      A0137RP Pinch
      A013859 Pull

  25. DISCONNECT HEATER WATER HOSE INLET A


    1. A01372J

      Loosen the hose clip and disconnect the heater water inlet hose A.

  26. DISCONNECT HEATER WATER OUTLET HOSE A

    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. A01374W

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

      Text in Illustration
      A0137RP Pinch
      A013859 Pull

      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

    A0135UNE01

    1. Remove the clip A and clip B, then separate the transmission shift cable from the manual transaxle.

    2. A0136KNE01

      Remove the clip A and clip B, then separate the transmission select cable from the manual transaxle.

  29. REMOVE CLUTCH RELEASE FORK RETURN TENSION SPRING


    1. A0138ACE02
      Text in Illustration
      *1 Spring Hanger

      Remove the clutch release fork return tension spring from the spring hanger.

      Note


      • If there is any rust or deformation in the tension spring, replace it.

      • If there is any damage in the tension spring damper, replace it.

  30. SEPARATE CLUTCH RELEASE CABLE ASSEMBLY


    1. A01391E

      Turn and loosen the clutch release cable adjusting nut.

    2. A01391Y

      Separate the clutch release cable assembly from the manual transaxle assembly.

  31. PLACE FRONT WHEELS FACING STRAIGHT A HEAD

  32. REMOVE STEERING COLUMN HOLE COVER PLATE

    A0136Y5

    1. Turn back the floor carpet and disengage the 2 claws from the steering column hole cover plate.

  33. SEPARATE NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    A01369HE02

    1. Hold the steering wheel assembly with the seat belt in order to prevent rotation and damage to the spiral cable.

    2. A0137IGE06
      Text in Illustration
      *a Matchmark

      Place matchmarks on the No. 2 steering intermediate shaft assembly and the steering gear assembly.

    3. Loosen bolt A and remove bolt B to separate the No. 2 steering intermediate shaft assembly.

  34. SEPARATE NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    A0137CHE02
    Text in Illustration
    *1 Clip A
    *2 Clip B

    1. Remove clip A and separate the No. 1 steering column hole cover sub-assembly from the body.

      Note

      Do not damage clip B.

  35. DRAIN MANUAL TRANSAXLE OIL


    1. Remove the filler plug and gasket.

    2. Remove the drain plug and gasket, and then drain the manual transaxle oil.

  36. REMOVE FRONT DRIVE SHAFT ASSEMBLY

    Click here

  37. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. Set the engine lifter.

    2. A0138Q1

      Remove the 4 bolts and nut from the engine mounting insulator RH.

    3. A0138IH

      Remove the 7 bolts and engine mounting insulator LH.

    4. A01388M

      Remove the 6 bolts, the engine assembly with transaxle and the front suspension crossmember from the vehicle.

    5. A0138UYE03
      Text in Illustration
      *1 Engine Hanger
      *2 No. 2 Engine Hanger
      *3 Stopper

      Install the 2 engine hangers with the 2 bolts.

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

      Tech Tips

      Part Name Part No.
      Engine Hanger 12281-40032
      No. 2 Engine Hanger 12282-40010
      Bolt 91671-80820

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

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

  38. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. A01389H

      Remove the bolt and the engine assembly with transaxle from the front suspension crossmember assembly.

  39. REMOVE STARTER ASSEMBLY


    1. A01374KE01

      Open the terminal cap, remove the nut and disconnect the wire harness from terminal 50.

    2. Open the terminal cap, remove the nut and disconnect the wire harness from terminal 30.

    3. Remove the bolt, and wire harness clamp.

    4. Remove the 2 bolts, and the starter.

  40. REMOVE FLYWHEEL HOUSING SIDE COVER

  41. REMOVE FLYWHEEL HOUSING UNDER COVER


    1. A0135X7

      Remove the 3 bolts and the flywheel housing under cover from the manual transaxle assembly.

  42. REMOVE MANUAL TRANSAXLE ASSEMBLY


    1. A013625

      Remove the 5 bolts and the manual transaxle assembly from the engine assembly.

      Note


      • To avoid damage to the knock pins, do not pry between the manual transaxle assembly and the engine assembly.

      • To avoid damage to the input shaft, do not forcefully shake the manual transaxle assembly.

  43. REMOVE CLUTCH COVER ASSEMBLY


    1. A0138RBE14
      Text in Illustration
      *a Matchmark

      Place matchmarks on the clutch cover assembly and the flywheel sub-assembly.

    2. Loosen each bolt by one turn at a time until the spring tension is released.

    3. Remove the 6 bolts, and pull off the clutch cover assembly with the clutch disc assembly.

      Note


      • Do not drop the clutch disc assembly.

      • When replacing the clutch disc assembly, be sure to replace it together with the clutch cover assembly as a set.

  44. REMOVE CLUTCH DISC ASSEMBLY

    Note

    Do not attach any oil or foreign matter to the lining part of the clutch disc assembly or the surfaces of the pressure plate and flywheel sub-assembly.

  45. 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.

  46. REMOVE NO. 1 IGNITION COIL


    1. A0138SF

      Disconnect the 3 connectors.

    2. Remove the 3 bolts and 3 No. 1 ignition coils.

  47. REMOVE SPARK PLUG


    1. A0137PG

      Remove the 3 spark plugs.

  48. REMOVE GENERATOR ASSEMBLY


    1. A013629E01

      Remove the terminal cap.

    2. Remove the nut and disconnect the wire harness from terminal B.

    3. Remove the nut and disconnect the wire harness from terminal D.

    4. Remove the bolt and disconnect the wire harness clamp from generator.

    5. A0138RAE02

      Remove the 2 bolts and generator.

  49. REMOVE FAN BELT ADJUSTING BAR


    1. A01381M

      Remove the bolt and fan belt adjusting bar from the timing chain or belt cover.

  50. REMOVE EXHAUST MANIFOLD


    1. A0137U7

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

    2. Remove the exhaust manifold gasket.

  51. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)


    1. A0137BB

      Remove the 2 bolts and No. 1 compressor mounting bracket.

  52. REMOVE NO. 1 WATER BY-PASS PIPE


    1. A0136SP

      Remove the bolt and 2 nuts.

    2. Loosen the hose clip and remove the No. 1 water by-pass pipe with water by-pass hose.

    3. Remove the water by-pass pipe gasket.

  53. REMOVE ENGINE OIL LEVEL DIPSTICK SUB-ASSEMBLY

  54. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A0137FF

      Disengage the 2 wire harness clamps from the engine oil level dipstick guide.

    2. Remove the bolt and engine oil level dipstick guide.

    3. A0138AIE01
      Text in Illustration
      *1 O-ring

      Remove the O-ring from the engine oil level dipstick guide.

  55. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE SUPPORT


    1. A0136CW

      Remove the engine oil level dipstick guide support.

  56. REMOVE THROTTLE BODY ASSEMBLY


    1. A0138CUE01

      Disconnect the throttle position sensor connector.

    2. Disconnect the idle speed control valve connector.

    3. A0136XTE01

      Remove the 3 bolts and throttle body.

  57. REMOVE THROTTLE BODY GASKET


    1. A0136NZE01

      Remove the gasket from the intake manifold.

  58. REMOVE FUEL DELIVERY PIPE


    1. A0136SOE01

      Disconnect the fuel earth cable from the heater hose pipe.

    2. Remove the fuel pipe clamp from the fuel tube connector.

    3. Pinch the tube connector and then pull out the fuel pipe.

      Note


      • Check if there is any dirt or other foreign objects around the connector before this operation and clean the connector as necessary.

      • Be careful of mud because the quick connector has O-rings which seal the pipe and connector that can be contaminated.

      • Do not use any tool in this operation.

      • Do not bend or twist the nylon tube. Protect the connector by covering it with a plastic bag.

      • When the pipe and the connector are stuck, push and pull the connector to release and pull the connector out carefully.

    4. A0136WAE01

      Disconnect the 3 ignition coil connectors.

    5. Disconnect the 3 injector connectors.

    6. Disconnect the 2 clamps and wire harness.

    7. A0136QT

      Remove the 2 bolts and delivery pipe together with the 3 injectors.

      Note

      Be careful not to drop the injectors when removing the delivery pipe.

    8. A0137PL

      Remove the 3 injector vibration insulators from the cylinder head.

  59. REMOVE FUEL INJECTOR ASSEMBLY


    1. A0137PM

      Pull out the 3 injectors from the fuel delivery pipe.

  60. REMOVE VACUUM SENSOR


    1. A01383I

      Disconnect the vacuum sensor connector.

    2. Remove the 2 bolts and vacuum sensor.

  61. REMOVE INTAKE MANIFOLD


    1. Disconnect the PCV hose.

    2. A0138RJ

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

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

  62. REMOVE THERMOSTAT


    1. A0138C2

      Remove the 2 bolts, water inlet, and thermostat.

    2. Remove the thermostat gasket from the thermostat.

  63. REMOVE CRANKSHAFT POSITION SENSOR


    1. A0136B3

      Disconnect the sensor connector.

    2. Remove the bolt and sensor.

  64. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY


    1. A0135Z2E01

      Disconnect the camshaft timing oil control valve connector.

    2. Remove the bolt, then remove the camshaft timing oil control valve.

  65. REMOVE OIL CONTROL VALVE FILTER


    1. A01369E

      Using an 8 mm socket hexagon wrench, remove the head taper screw plug.

    2. Remove the oil control valve filter and gasket.

  66. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. Disconnect the engine oil pressure switch assembly connector.

    2. A01381ZE01
      Text in Illustration
      *1 24 mm Deep Socket Wrench

      Using a 24 mm deep socket wrench, remove the oil pressure switch.

  67. REMOVE KNOCK SENSOR


    1. Disconnect the knock control sensor connector.

    2. A013640E01

      Remove the bolt and knock control sensor.

  68. REMOVE CAMSHAFT POSITION SENSOR


    1. A0136GO

      Disconnect the sensor connector.

    2. Remove the bolt and sensor.

  69. REMOVE ENGINE COOLANT TEMPERATURE SENSOR


    1. A0136H1E01

      Disconnect the engine coolant temperature sensor connector.

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

      SST
      09817-33190