Engine Assembly Removal

Remove the oil filler cap.

Remove the oil drain plug and drain the oil into a container.

Remove the radiator cap sub-assembly from the radiator assembly.

Loosen the radiator drain cock plug and cylinder block drain cock plug, then drain the coolant.

HINT:

Collect the coolant in a container and dispose of it according to the regulations in your area.

Using a 6 mm socket hexagon wrench, remove the drain plug and gasket, and drain ATF.

Install a new gasket and the drain plug.

Torque:

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

Remove the filler plug and the gasket.

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

Install a new gasket and the drain plug.

Torque:

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

Remove the 4 bolts, 4 nuts and outer cowl top panel sub-assembly.

Remove the 2 nuts and cover.

Using SST and 19 mm socket wrench, loosen the V-ribbed belt tensioner arm clockwise, then remove the V-ribbed belt.

SST

09216-42010

NOTICE:

1. Be sure to connect SST and the tools so that they are in line during use.
   
2. When retracting the tensioner, turn it clockwise slowly for 3 seconds or more. Do not apply force rapidly.
   
3. After the tensioner is fully retracted, do not apply force any more than necessary.
   

Remove the 2 bolts, clamp and air cleaner inlet.

Disconnect the mass air flow meter connector (^*1).

Disconnect the purge VSV connector (^*2).

Disconnect the 2 purge VSV vacuum hoses (^*3).

Disconnect the purge line hose from the clamp (^*4).

Disconnect the No. 2 ventilation hose from the air cleaner hose.

Lock the No. 1 air cleaner hose clamp, and then disconnect the No. 1 air cleaner hose from the throttle body.

Remove the 2 bolts and air cleaner cap.

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

Disconnect the hose clamp.

Remove the 3 bolts and air cleaner case.

Loosen the bolt and nut, and remove the battery clamp.

Remove the battery and battery tray.

Remove the 2 bolts and No. 2 mounting stay RH.

Remove the bolt and disconnect the ground cable.

Remove the 3 bolts and the engine moving control rod with bracket.

Remove the 3 bolts and No. 2 mounting bracket RH.

Remove the clamp and disconnect the vacuum hose connector.

Remove the clamp and disconnect the radiator hose inlet.

Remove the clamp and disconnect the radiator hose outlet.

Disconnect the oil cooler inlet hose from the radiator assembly.

Disconnect the oil cooler outlet hose from the radiator assembly.

Disconnect the heater inlet water hose.

Disconnect the heater outlet water hose.

Disconnect the engine wire from the engine room relay block.

1. Remove the nut and separate the wire harness.
   

2. Using a screwdriver, unlock the engine room R/B. Pull the engine room R/B upward.
   

3. Disconnect the engine wire connectors.
   

Remove the clamp from the bracket.

Remove the 2 bolts and clamp from the body.

Remove the clip and nut, and separate the control lever.

Separate the clamp and separate the cable from the transaxle.

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

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

Disconnect the No. 1 oil reservoir to pump hose.

Disconnect the return tube sub-assembly.

Remove the No. 1 fuel pipe clamp.

Disconnect the connector from the tube while pinching part A with your fingers as shown in the illustration.

NOTICE:

1. Check for contamination in the pipe and around the connector. Clean if necessary and then disconnect the connector.
   
2. Disconnect the connector by hand.
   
3. Do not bend, fold or rotate the nylon tube.
   
4. If the pipe and connector are stuck together, push and pull the connector until it becomes free.
   
5. Put the pipe and connector ends in vinyl bags to prevent damage and contamination.
   

Disconnect the generator connector.

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

Remove the bolt and wire harness clamp bracket.

Remove the wire harness clamps.

Remove the 2 bolts and generator assembly.

Disconnect the connector.

Remove the 4 bolts and separate the compressor.

HINT:

Hang up the hoses instead of detaching them.

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

SST

09930-00010

NOTICE:

Loosen the staked part of the nut completely, otherwise the thread of the drive shaft may be damaged.

While applying the brakes, remove the front axle hub nut.

Remove the nut and separate the front stabilizer link assembly.

HINT:

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

Remove the bolt and clip, and separate the speed sensor wire and flexible hose from the shock absorber.

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

NOTICE:

1. Prevent foreign matter from adhering to the speed sensor.
   
2. Be careful not to damage the speed sensor.
   

Remove the cotter pin and nut.

Using SST, separate the tie rod end sub-assembly from the steering knuckle.

SST

09628-00011

NOTICE:

1. Make sure that the string of the SST is securely tied to the vehicle.
   
2. Be careful not to damage the ball joint dust cover.
   
3. Be careful not to damage the steering knuckle.
   
4. Be careful not to damage the front disc brake dust cover.
   

Remove the bolt and 2 nuts, and separate the front suspension lower No. 1 arm from the lower ball joint.

Put matchmarks on the front drive shaft assembly and the axle hub.

Using a plastic hammer, separate the front drive shaft assembly from the front axle assembly.

NOTICE:

Be careful not to damage the drive shaft boot and speed sensor rotor.

Remove the flywheel housing under cover.

Turn the crankshaft to gain access and remove the 6 bolts while holding the crankshaft pulley bolt with a wrench.

HINT:

There will be one black colored bolt.

Remove the 2 bolts and exhaust pipe support bracket.

Secure the steering wheel with the seat belt in order to prevent rotation.

HINT:

This operation is useful to prevent damage to the spiral cable.

Remove the bolt and slide the steering sliding yoke.

NOTICE:

Do not separate the steering sliding yoke from the power steering link assembly.

Put matchmarks on the steering sliding yoke and the power steering link assembly.

Separate the steering sliding yoke from the power steering link assembly.

Set the engine lifter.

Remove the 4 bolts, 2 nuts and frame side rail plate RH and LH.

Remove the 4 bolts, 2 nuts and front suspension member brace rear RH and LH.

Carefully remove the engine assembly from the vehicle.

Install the 2 engine hangers as shown in the illustration.
Parts No.:

Torque:

38 N*m{387 kgf*cm, 28 ft.*lbf}

Using a chain block and an engine sling device, hang the engine assembly.

Disconnect the oil pressure switch connector.

Loosen the 2 bolts and remove the vane pump from the engine.

A/T:
Remove the nut from the engine mounting insulator LH.

M/T:
Remove the bolt from the engine mounting insulator LH.

Remove the nut from the engine mounting insulator RH.

Remove the bolt from the engine mounting insulator FR.

M/T:
Remove the bolt from the engine lateral control rod.

Raise the engine assembly and separate the front frame.

Using SST, remove the front drive shaft assembly LH.

SST

09520-01010
09520-24010(09520-32040)

NOTICE:

1. Be careful not to damage the drive shaft dust cover, boot, and oil seal.
   
2. Be careful not to drop the drive shaft assembly.
   

Using a screwdriver, remove the bearing bracket hole snap ring.

Remove the bolt and front drive shaft assembly RH from the drive shaft bearing bracket.

NOTICE:

Do not damage the boot and oil seal.

Disconnect the terminal 50 connector from the starter assembly.

Remove the nut and disconnect the wire harness from terminal 30.

Remove the 3 bolts, clutch flexible hose bracket and starter assembly.

Disconnect the terminal 50 connector from the starter assembly.

Remove the nut and disconnect the wire harness from terminal 30.

Remove the 2 bolts and starter assembly.

Using SST, hold the crankshaft.

SST

09213-54015(91651-60855)
09330-00021

Remove the 8 bolts, rear spacer, drive plate and front spacer.

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

Loosen the 6 bolts one turn at a time until spring tension is released.

Remove the 6 bolts and pull off the clutch cover assembly.

NOTICE:

Do not drop the clutch disc assembly.

Using SST, hold the crankshaft.

SST

09213-54015(91651-60855)
09330-00021

Remove the 8 bolts and flywheel.

Fix the engine onto a engine stand with the bolts.

Remove the 2 wire harness clamps.

Disconnect the 4 fuel injector connectors.

Remove the 2 bolts, then remove the fuel delivery pipe together with the 4 fuel injectors.

NOTICE:

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

Remove the 2 delivery pipe spacers from the cylinder head.

Remove the 4 insulators from the cylinder head.

Remove the 5 bolts, 2 nuts, and intake manifold.

Remove the gasket from the intake manifold.

Remove the intake manifold insulator from the cylinder block.

Remove the 3 bolts and drive shaft bearing bracket.

Remove the bolt and oil level gauge guide.

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

Remove the bolt, nut and stay.

Remove the bolt, nut and stay.

Remove the 4 bolts and No. 1 insulator.

Disconnect the air-fuel ratio sensor connector.

Remove the 5 nuts, manifold converter and gasket.

Remove the 2 nuts and disconnect the water inlet from the cylinder block.

Remove the gasket from the thermostat.

Remove the bolt, 2 nuts and No. 1 water by-pass pipe with the gasket.

Remove the bolt, 2 nuts and oil cooler pipe with the gasket.

Remove the 3 bolts and engine mounting bracket RH.

Remove the bolt, nut and belt tensioner.

Remove the 4 bolts and 4 ignition coils.

Disconnect the camshaft timing oil control valve assembly connector.

Remove the bolt and camshaft timing oil control valve assembly.

Disconnect the sensor connector.

Remove the nut and sensor.

Remove the bolt and radio setting condenser.

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

Using SST, remove the sensor and gasket.

SST

09817-33190