Engine Assembly - Removal

1. Discharge fuel system pressure

2. Remove battery

3. Remove battery tray

4. Remove front wheels

5. Remove engine under cover lh

6. Remove engine under cover rh

7. Remove engine under cover sub-assembly (for rough road area specification vehicles)

8. Drain engine coolant

9. Drain automatic transaxle fluid (for automatic transaxle)

10. Drain manual transaxle oil (for manual transaxle)

11. Remove front wiper arm head cap (for hatchback)

12. Remove front wiper arm head cap (for sedan)

13. Remove front wiper arm and blade assembly lh (for hatchback)

14. Remove front wiper arm and blade assembly lh (for sedan)

15. Remove front wiper arm and blade assembly rh (for hatchback)

16. Remove front wiper arm and blade assembly rh (for sedan)

17. Remove hood to cowl top seal (for hatchback)

18. Remove cowl side ventilator sub-assembly lh (for sedan)

19. Remove cowl side ventilator sub-assembly rh (for sedan)

20. Remove cowl top ventilator louver sub-assembly (for hatchback lhd)

21. Remove cowl top ventilator louver lh (for hatchback lhd)

22. Remove cowl top ventilator louver sub-assembly (for hatchback rhd)

23. Remove cowl top ventilator louver lh (for hatchback rhd)

24. Remove cowl top ventilator louver sub-assembly (for sedan rhd)

25. Remove cowl top ventilator louver sub-assembly (for sedan lhd)

26. Remove front wiper motor and link (for hatchback)

27. Remove front wiper motor and link (for sedan)

28. Remove cowl to register duct sub-assembly no. 2 (for hatchback)

29. Remove front air shutter seal (for sedan)

30. Remove cowl top panel outer (for hatchback)

31. Remove cowl top panel outer (for sedan)

32. Remove air cleaner assembly

33. Remove air cleaner bracket

34. Remove battery carrier

35. Disconnect radiator hose no. 3

36. Disconnect radiator reservoir tank hose

37. Disconnect radiator hose no. 2

38. Disconnect oil cooler inlet hose (for automatic transaxle)

39. Disconnect oil cooler outlet hose (for automatic transaxle)

40. Remove cylinder head cover no. 2

41. Separate transmission control cable assembly (for automatic transaxle)

42. Separate transmission control cable assembly (for manual transaxle)

43. Disconnect union to check valve hose

44. Disconnect heater water outlet hose a (from heater unit)

45. Disconnect heater water hose inlet a

46. Disconnect fuel tube sub-assembly

47. Remove fan & generator v belt

48. Separate with pulley compressor assembly (w/ air conditioning system)

49. Separate clutch release cylinder assembly (for manual transaxle)

50. Disconnect engine wire

51. Remove column hole cover silencer sheet

52. Separate steering sliding yoke sub-assembly

53. Separate steering column hole cover sub-assembly no. 1

54. Remove shift lever knob sub-assembly (for manual transaxle)

55. Remove shifting hole cover sub-assembly (for hatchback)

56. Remove console box cover rear (for hatchback)

57. Remove console box assembly rear (for hatchback)

58. Remove instrument panel finish panel lower center (for sedan)

59. Remove instrument panel finish panel end lh (for sedan)

60. Remove instrument pad lower lh (for sedan)

61. Remove upper console panel sub-assembly (for sedan)

62. Remove console upper rear panel sub-assembly (for sedan)

63. Remove console box carpet (for sedan)

64. Remove rear console box assembly (for sedan)

65. Remove oxygen no. 2 sensor

66. Remove exhaust pipe assembly front

67. Remove front axle shaft lh nut

68. Remove front axle shaft rh nut

69. Separate speed sensor front lh (w/ abs)

70. Separate speed sensor front rh (w/ abs)

71. Separate front flexible hose lh (w/o abs)

72. Separate front flexible hose rh (w/o abs)

73. Separate tie rod end sub-assembly lh

74. Separate tie rod end sub-assembly rh

75. Separate front stabilizer link assembly lh

76. Separate front stabilizer link assembly rh

77. Separate front suspension arm sub-assembly lower no. 1 lh

78. Separate front suspension arm sub-assembly lower no. 1 rh

79. Separate front axle assembly lh

80. Separate front axle assembly rh

81. Remove automatic transmission case protector (w/o abs)

82. Remove front drive shaft assembly lh

83. Remove front drive shaft assembly rh

84. Remove flywheel housing under cover (for automatic transaxle)

85. Remove drive plate and torque converter clutch setting bolt (for automatic transaxle)

86. Remove engine assembly with transaxle

87. Remove front suspension crossmember sub-assembly

88. Remove ventilation hose

89. Remove ventilation hose no. 2

90. Remove fuel tube sub-assembly

91. Remove water filler sub-assembly

92. Remove heater water hose inlet a

93. Remove flywheel housing side cover

94. Remove starter assembly

95. Remove automatic transaxle assembly (for automatic transaxle)

96. Remove drive plate and ring gear sub-assembly (for automatic transaxle)

97. Remove control cable bracket (for manual transaxle)

98. Remove manual transaxle assembly (for manual transaxle)

99. Remove clutch cover assembly (for manual transaxle)

100. Remove clutch disc assembly (for manual transaxle)

101. Remove flywheel sub-assembly (for manual transaxle)

102. Remove ignition coil no. 1

103. Remove oil level gauge sub-assembly

104. Remove generator assembly

105. Remove intake manifold

106. Remove water by-pass pipe no. 1

107. Remove booster vacuum tube

108. Remove engine wire

109. Remove wire harness clamp bracket

110. Remove exhaust manifold heat insulator no. 1

111. Remove manifold support bracket

112. Remove exhaust manifold

113. Remove drive shaft heat insulator sub-assembly

​

1. Disconnect the cable from the battery terminal.

2. Loosen the nut and remove the battery clamp.

3. Remove the battery.

NOTICE:

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. Loosen the radiator drain cock plug.

2. Remove the radiator cap sub-assembly.

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

   
   
   
   

1. Remove the drain plug and gasket, and drain the ATF.

2. Install a new gasket and the drain plug.

   Torque:

   49 N*m{500 kgf*cm, 36 ft.*lbf}

1. Remove the filler plug and the gasket.

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

3. Install a new gasket and the drain plug.

   Torque:

   39 N*m{400 kgf*cm, 29 ft.*lbf}

1. Using a screwdriver with its tip wrapped in protective tape, disengage the claw and remove the 2 front wiper arm head caps.

1. Using a screwdriver with its tip wrapped in protective tape, disengage the claw and remove the 2 front wiper arm head caps.

1. Operate the wiper, then stop the windshield wiper motor in the automatic stop position.

2. Remove the nut and front wiper arm.

1. Operate the wiper, then stop the windshield wiper motor in the automatic stop position.

2. Remove the nut and front wiper arm.

HINT:

Use the same procedure as for the LH side.

HINT:

Use the same procedure as for the LH side.

1. Disengage the 7 clips and remove the hood to cowl top seal.

1. Using a screwdriver with its tip wrapped in protective tape, disengage the 3 claws and remove the cowl side ventilator sub-assembly LH.

HINT:

Use the same procedure as for the LH side.

1. Disengage the 2 hooks and remove cowl top ventilator louver center No. 1.

2. Disconnect the washer hose.

3. Disengage the 11 claws and clip.

4. Disconnect the washer hose and remove the cowl top ventilator louver sub-assembly.

1. Remove the 2 clips.

2. Disengage the 4 claws and remove the cowl top ventilator louver LH.

1. Disconnect the washer hose.

2. Disengage the 10 claws and clip and remove the cowl top ventilator louver sub-assembly.

1. Remove the clip.

2. Disengage the 4 claws and remove the cowl top ventilator louver LH.

1. Disengage the 2 clips, the 6 claws and the 10 hooks.

2. Remove the cowl top ventilator louver sub-assembly.

3. Disconnect the washer hoses.

4. Disengage the 5 hooks.

1. Disengage the 3 clips, the 4 claws and the 8 hooks.

2. Remove the cowl top ventilator louver sub-assembly.

3. Disconnect the washer hoses.

4. Disengage the 5 hooks.

1. Remove the 2 bolts.

2. Slide the wiper link. Disengage the meshing of the rubber pin, then disconnect the connector and remove the front wiper motor and link.

1. Remove the 2 bolts.

2. Slide the wiper link. Disengage the meshing of the rubber pin, then disconnect the connector and remove the front wiper motor and link.

1. Disengage the claw and remove cowl to register duct sub-assembly No. 2.

1. Disengage the 3 claws and remove the front air shutter seal.

1. Disengage the wire harness clamp.

2. Remove the 9 bolts and remove the cowl top panel outer.

1. Disengage the wire harness clamp.

2. Remove the 2 bolts and remove the cowl top to cowl inner brace.

3. Remove the 8 bolts and remove the cowl top panel outer.

1. Separate the intake air flow meter connector and wire harness clamp.

2. Separate the fuel vapor feed hose and fuel vapor feed hose No. 1 from the vacuum switching valve assembly.

3. Separate the vacuum switching valve connector and wire harness clamp.

4. Separate the ventilation hose from the air cleaner hose.

5. Release the air cleaner cap sub-assembly with air cleaner hose No. 1.

6. Loosen the air cleaner hose clamp on the throttle body side and remove the air cleaner cap and air cleaner hose.

7. Remove the air cleaner element.

8. Separate the wire harness clamp from the air cleaner case.

9. Remove the 2 bolts and remove the air cleaner case with air cleaner inlet No. 1.

1. Separate the wire harness clamp from the air cleaner bracket.

2. Remove the 2 bolts and remove the air cleaner bracket.

1. Separate the wire harness clamp from the battery carrier.

2. Remove the 5 bolts and remove the battery carrier.

1. Disconnect radiator hose No. 3 from the water filler.

1. Disconnect the radiator reservoir tank hose from the water filler.

1. Disconnect radiator hose No. 2 from the water inlet.

1. Loosen the clip and disconnect the oil cooler inlet hose.

1. Loosen the clip and disconnect the oil cooler outlet hose.

1. Remove the 4 nuts and cylinder head cover No. 2.

1. Remove the nut and disconnect the control cable from the control shaft lever.

2. Remove the clip and disconnect the control cable from the control cable bracket.

1. Remove the 2 clips and the 2 washers, and disconnect the 2 cables from the transaxle.

2. Remove the 2 clips and disconnect the 2 cables from the control cable bracket.

1. Disconnect the union to check valve hose from the booster vacuum tube.

1. Disconnect heater water outlet hose A from the heater unit.

1. Disconnect heater water inlet hose A from the heater unit.

1. Remove fuel pipe clamp No. 1.

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

   NOTICE:

   1. Remove any dirt and foreign matter from the fuel tube connector before performing this work.
      
   2. Do not allow any scratches or foreign matter on the parts when disconnecting, as the fuel tube connector has the O-rings that seal the pipe.
      
   3. Perform this work by hand. Do not use any tools.
      
   4. Do not forcibly bend, twist or turn the nylon tube.
      
   5. Protect the disconnected parts by covering them with vinyl bags after disconnecting the fuel tube.
      
   6. If the fuel tube connector and pipe are stuck, push and pull to release them.
      

1. Disconnect the connector.

2. Remove the 4 bolts and separate the with pulley compressor assembly.

   HINT:

   Remove the compressor assembly together with the low and high pressure hoses, then suspend them from the body with a piece of rope.

1. Remove the 4 bolts, then separate the clutch release cylinder.

   HINT:

   Suspend the clutch release cylinder with a piece of rope so as not to overload the clutch pipe.

1. Pull up the lever and disconnect the connector of the engine control computer.

2. Remove the 2 connectors and clamp from the engine room junction block and disconnect the wire harness.

3. Remove the bolt and separate the transaxle earth wire of the engine room wire harness.

4. Disconnect all the wire harnesses and connectors. Make sure that no wire harness is connected between the body and engine.

1. Remove the floor carpet and 2 clips and remove the column hole cover silencer.

1. Use a seat belt to fix the steering wheel assembly, in order to avoid breakage of the spiral cable.

2. Place matchmarks on the sliding yoke of the steering intermediate shaft assembly and the steering gear assembly.

   Text in Illustration

   *1	Bolt A
   *2	Bolt B
   *a	Matchmark

3. Loosen bolt A, remove bolt B and separate the steering intermediate shaft assembly.

1. Remove clip A, separate clip B from the body and separate No. 1 steering column hole cover.

   Text in Illustration

   *1	Clip A
   *2	Clip B

   NOTICE:

   Do not damage clip B.

1. Disengage the 8 claws and remove the console box rear cover.

1. Remove bolt <F>.

2. Disengage the 2 clips and remove the console box rear.

1. Disconnect the sensor connector.

2. Remove the grommet and pass the sensor connector out of the cabin through the floor panel.

3. Using SST, remove heated oxygen sensor No. 2.

   SST

   09224-00010
   

1. Remove the 2 bolts and 2 springs and separate the exhaust tail pipe assembly.

2. Remove the 2 bolts and 2 springs and separate the exhaust manifold.

3. Remove the 3 exhaust pipe supports and remove the exhaust pipe assembly front.

1. Using SST and a hammer, release the staked part of the axle hub nut.

   SST

   09930-00010
   

   NOTICE:

   1. Insert SST into the groove with the flat surface facing up.
      
   2. Do not damage the tip of SST using grinders.
      
   3. Completely unstake the staked part before removing the axle hub nut.
      
   4. Do not damage the threads of the drive shaft.
      

2. Using a 30 mm socket wrench, remove the axle hub nut.

HINT:

Use the same procedure as for the LH side.

1. Remove the bolt and separate the speed sensor and flexible hose.

2. Remove the bolt and separate the speed sensor from the steering knuckle.

   NOTICE:

   1. Keep the speed sensor tip and installation portion free of foreign matter.
      
   2. Remove the speed sensor without turning it from its original installation angle.
      

HINT:

Use the same procedure as for the LH side.

1. Remove the bolt and separate the flexible hose.

HINT:

Use the same procedure as for the LH side.

1. Remove the cotter pin and castle nut.

2. Install SST (spacer B) to the threaded section of the tie rod end.

   SST

   09960-20010 (09961-02060)
   

   NOTICE:

   Make sure the upper ends of the threaded section of the tie rod end and SST (spacer B) are aligned.

3. Using SST, separate the tie rod end from the front axle assembly.
   

   
   
   
   

   SST

   09960-20010 (09961-02010)
   

   NOTICE:

   1. Make sure to tie the string of SST to the vehicle to prevent SST from dropping.
      
   2. Install SST so that A and B are parallel.
      
   3. Be sure to place the wrench on the part indicated in the illustration.
      
   4. Do not damage the ball joint dust cover.
      
   5. Do not damage the front disc brake dust cover.
      

HINT:

Use the same procedure as for the LH side.

1. Remove the nut and separate the stabilizer link from the shock absorber.

   HINT:

   If the ball joint turns together with the nut, use a socket hexagon wrench 6 to hold the stud.

HINT:

Use the same procedure as for the LH side.

1. Remove the clip and castle nut.

2. Install SST (spacer B) to the threaded section of the lower ball joint.

   SST

   09960-20010 (09961-02060)
   

   NOTICE:

   Make sure the upper ends of the threaded section of the lower ball joint and SST (spacer B) are aligned.

3. Using SST, separate the front lower suspension arm from the front axle assembly.
   

   
   
   
   

   SST

   09960-20010 (09961-02010)
   

   NOTICE:

   1. Make sure to tie the string of SST to the vehicle to prevent SST from dropping.
      
   2. Install SST so that A and B are parallel.
      
   3. Be sure to place the wrench on the part indicated in the illustration.
      
   4. Do not damage the lower ball joint dust cover.
      
   5. Do not damage the drive shaft outboard joint boots.
      
   6. Do not damage the front disc brake dust cover.
      

HINT:

Use the same procedure as for the LH side.

1. Using a plastic hammer, tap the end of the drive shaft and disengage the fitting between the drive shaft and front axle.

   HINT:

   If it is difficult to disengage the fitting, tap the end of the drive shaft with a brass bar and hammer.

2. Push the front axle out of the vehicle to remove the drive shaft from the front axle.

   NOTICE:

   1. Do not push the front axle further out of the vehicle than is necessary.
      
   2. Do not damage the outboard joint boot.
      
   3. Do not damage the speed sensor rotor.
      
   4. Suspend the drive shaft with a piece of string or the equivalent.
      

HINT:

Use the same procedure as for the LH side.

1. Remove the 2 bolts and automatic transmission case protector.

1. Using SST, remove the drive shaft.

   SST

   09520-01010
   09520-24010 (09520-32040)
   

   NOTICE:

   1. Do not damage the oil seal.
      
   2. Do not damage the inboard joint boot.
      
   3. Do not drop the drive shaft.
      

1. Using a screwdriver and hammer, remove the drive shaft.

   NOTICE:

   1. Do not damage the oil seal.
      
   2. Do not damage the inboard joint boot.
      
   3. Do not drop the drive shaft.
      

1. Remove the 6 torque converter set bolts.

1. Set the engine lifter.

2. Remove the 5 bolts and nut and remove the engine mounting insulator RH.

3. Remove the through bolt and nut and separate the engine mounting insulator LH.

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

1. Remove the bolt and remove the radio setting condenser.

2. Remove the bolt and remove the oxygen sensor wiring bracket.

3. Install the engine hangers with the bolts, as shown in the illustration.

   Torque:

   40 N*m{408 kgf*cm, 30 ft.*lbf}

   Part No.:
   12281-21010 for engine hanger
   91642-81025 for bolt
   

4. Using an engine sling device and a chain block, suspend the engine assembly with transaxle and front suspension crossmember.

5. Remove the through bolt from the engine moving control rod and remove the front suspension crossmember.

1. Loosen the 2 clips and remove the ventilation hose.

1. Loosen the clip and remove ventilation hose No. 2.

1. Disengage the claw and remove fuel pipe clamp No. 2.

2. Pinch the fuel tube connector retainer from both sides, disconnect the fuel tube connector and separate the fuel tube from the pipe.

   NOTICE:

   1. Remove any dirt and foreign matter from the fuel tube connector before performing this work.
      
   2. Do not allow any scratches or foreign matter on the parts when disconnecting, as the fuel tube connector has the O-rings that seal the pipe.
      
   3. Perform this work by hand. Do not use any tools.
      
   4. Do not forcibly bend, twist or turn the nylon tube.
      
   5. Protect the disconnected parts by covering them with vinyl bags after disconnecting the fuel tube.
      
   6. If the fuel tube connector and pipe are stuck, push and pull to release them.
      

1. Disconnect radiator hose No. 1 from the cylinder head.

2. Remove the 2 nuts and remove the water filler sub-assembly.

1. Disconnect heater water inlet hose A from the cylinder head.

1. Disengage the claw by pushing it upward and remove the flywheel housing side cover.

1. Remove the terminal cap.

2. Remove the nut and disconnect terminal 30.

3. Disconnect the connector.

4. Remove the 2 bolts and remove the starter assembly.

1. Remove the 7 bolts and remove the automatic transaxle with torque converter.

1. Hold the crankshaft with SST.

   SST

   09960-10010 (09962-01000, 09963-01000)
   

2. Remove the 6 bolts, drive plate spacer FR, drive plate and ring gear sub-assembly and drive plate spacer RR.

1. Remove the 2 bolts and the control cable bracket.

1. Remove the 7 bolts and the manual transaxle.

1. Align the matchmark on the clutch cover assembly with the one on the flywheel.

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

3. Remove the set bolts and pull off the clutch cover.

   NOTICE:

   Do not drop the clutch disc.

1. Hold the crankshaft with SST.

   SST

   09960-10010 (09962-01000, 09963-01000)
   

2. Remove the 6 bolts and flywheel.

1. Disconnect the connectors of the ignition coils.

2. Remove the bolt and remove all the ignition coils.

1. Remove the terminal cap.

2. Separate the connector and harness clamp.

3. Remove the nut and remove terminal B.

4. Remove fan belt adjusting slider fixing bolts A and B and remove the fan belt adjusting slider.

5. Remove fixing bolt B and remove the generator.

1. Disconnect the union to connector tube hose from the booster vacuum tube.

2. Disconnect the engine wire from the intake manifold.

3. Disconnect the water by-pass hose from the cylinder head.

4. Disconnect the water by-pass hose from water by-pass pipe No. 1.

5. Disconnect the throttle with motor body assembly connector.

6. Remove the 3 bolts and 2 nuts in the order shown in the illustration and remove the intake manifold.

7. Remove the gasket from the intake manifold.

1. Remove the 2 bolts and 2 nuts and remove water by-pass pipe No. 1.

1. Remove the 2 bolts and remove the booster vacuum tube.

1. Disconnect all sensor connectors and wire harness clamps from the engine assembly and remove the engine wire harness.

1. Remove the 2 bolts and remove the 2 wire harness clamp brackets.

1. Remove the 4 bolts and remove the exhaust manifold heat insulator.

1. Remove the 3 bolts and remove the manifold support bracket.

1. Remove the 3 bolts and 2 nuts and remove the exhaust manifold.

1. Remove the bolt and nut and remove the drive shaft heat insulator.