Part 1
REPLACEMENT1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
2. REMOVE FRONT WHEEL
3. REMOVE ENGINE UNDER COVER LH
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE FRONT FENDER APRON SEAL RH
6. DRAIN COOLANT
7. DRAIN AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
a. Using a 10 mm hexagon wrench, remove the drain plug and a gasket. Drain automatic transaxle fluid.
b. Install a new gasket and the drain plug.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
8. DRAIN MANUAL TRANSAXLE OIL (M/T TRANSAXLE)
a. Install a new gasket and the drain plug after draining transaxle oil.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
9. REMOVE BATTERY
10. REMOVE AIR CLEANER ASSEMBLY
11. REMOVE ENGINE COVER SUB-ASSEMBLY NO. 1
12. DISCONNECT RADIATOR HOSE INLET
13. DISCONNECT RADIATOR HOSE OUTLET
14. DISCONNECT OIL COOLER INLET HOSE (A/T TRANSAXLE)
15. DISCONNECT OIL COOLER OUTLET HOSE (A/T TRANSAXLE)
16. REMOVE ENGINE MOVING CONTROL ROD W/ BRACKET
a. Remove the 3 bolts and the engine moving control rod w/ bracket.
17. REMOVE ENGINE MOUNTING STAY NO. 2 RH
18. REMOVE ENGINE MOUNTING BRACKET NO. 2 RH
19. REMOVE FAN AND GENERATOR V BELT
SST 09249-63010
20. DISCONNECT OIL RESERVOIR TO PUMP HOSE NO. 1
a. Remove the clip and disconnect the hose.
21. DISCONNECT RETURN TUBE SUB-ASSEMBLY
a. Remove the clip and disconnect the return tube.
22. DISCONNECT UNION TO CONNECTOR TUBE HOSE
23. DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (A/T TRANSAXLE)
24. DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (M/T TRANSAXLE)
25. DISCONNECT FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (M/T TRANSAXLE)
26. REMOVE CLUTCH RELEASE CYLINDER ASSEMBLY (M/T TRANSAXLE)
a. Remove the bolt and flexible hose.
b. Remove the 2 bolts and clutch release cylinder.
27. DISCONNECT HEATER INLET WATER HOSE
28. DISCONNECT HEATER OUTLET WATER HOSE
29. DISCONNECT FUEL TUBE SUB-ASSEMBLY
30. DISCONNECT ENGINE WIRE
a. Disconnect the engine wire from engine ECU and junction block.
b. Disconnect the engine wire from engine room junction block.
1) Remove the nut fixing the wire harness.
2) Using a screwdriver, unlock the engine room junction block. Disconnect the engine wire by pulling it upward.
3) Disconnect the connectors.
c. Pull out the engine wire.
d. Disconnect the B terminal of the generator.
e. Remove the body ground.
f. Remove the starter connector.
31. DISCONNECT ENGINE WIRE NO. 2
a. Remove the nut and disconnect the terminal 30 of the starter.
32. REMOVE GENERATOR ASSEMBLY
33. REMOVE COMPRESSOR AND MAGNETIC CLUTCH
HINT: Hang up the hoses instead of detaching.
34. REMOVE EXHAUST PIPE ASSEMBLY FRONT
35. REMOVE FRONT STABILIZER LINK ASSEMBLY LH
a. Using a 6 mm socket hexagon wrench to fix the stud bolt.
b. Remove the nut and the stabilizer bar link.
36. REMOVE FRONT STABILIZER LINK ASSEMBLY RH
HINT: Perform the same procedure on the opposite side.
37. REMOVE FRONT AXLE HUB LH NUT
a. Using SST and a hammer, unstake the staked part of the lock nut.
SST 09930-00010
NOTICE:
- When removing the nut, unstake the staked part of it completely.
- Do not damage the threads of the drive shaft.
- Be sure not to sharpen the tip of the SST.
- Set the SST to the groove with the flat face upward.
b. Using a 30 mm socket wrench, remove the lock nut.
38. REMOVE FRONT AXLE HUB RH NUT
SST 09930-00010
HINT: Perform the same procedure on the opposite side.
39. REMOVE SPEED SENSOR FRONT LH (W/ ABS)
NOTICE: Keep the tip and connection part of speed sensor off foreign materials.
40. REMOVE SPEED SENSOR FRONT RH (W/ ABS)
HINT: Perform the same procedure on the opposite side.
41. DISCONNECT TIE ROD ASSEMBLY LH
a. Remove the cotter pin and a castle nut.
b. Using SST, disconnect the tie rod end from the steering knuckle.
SST 09628-62011
NOTICE: Be careful not to damage the cover of the ball joint.
42. DISCONNECT TIE ROD ASSEMBLY RH
SST 09628-62011
HINT: Perform the same procedure on the opposite side.
43. DISCONNECT FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 LH
a. Remove the bolt and 2 nuts shown in the illustration.
b. Using a plastic hammer, disconnect the drive shaft from the axle hub.
44. DISCONNECT FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 RH
HINT: Perform the same procedure on the opposite side.
45. REMOVE DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT (A/T TRANSAXLE)
a. Fix the crankshaft and remove the 6 set bolts.
46. REMOVE STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY
a. Loosen the sliding yoke bolt.
b. Place matchmarks on the intermediate shaft and control valve shaft.
c. Remove the bolt, and the steering intermediate shaft.
d. To prevent form rotating the steering wheel, fix the wheel with seat belt.
HINT: The operation is useful to prevent the damage of the spiral cable.
47. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
a. Set the engine lifter.
b. Remove the 4 bolts, 2 nuts and frame side rail plate subassembly RH and LH.
c. Remove the 4 bolts, 2 nuts and front suspension member brace rear RH and LH.
d. Carefully, remove the engine assembly from the vehicle.
e. Install the 2 engine hangers as shown in the illustration.
Parts No.:
No. 1 engine hanger 12281-28010
No. 2 engine hanger 12282-28010
Bolt 91512-61020
Torque: 38 Nm (387 kgf-cm, 28 ft. lbs.)
f. Using the chain block and engine sling device, hang the engine assembly.
48. REMOVE VANE PUMP ASSEMBLY
a. Disconnect the PS oil pressure switch connector.
b. Remove the 2 bolts and the vane pump from the engine.
49. REMOVE FRONT FRAME ASSEMBLY
a. Remove a nut installing the engine mounting insulator LH (A/T).
b. Remove a bolt installing the engine mounting insulator LH (M/T).
c. Remove a nut installing the engine mounting insulator RH.
d. Remove a bolt installing the engine mounting insulator FR.
e. Remove the bolt installing the engine lateral control rod (M/T).
f. Raise the engine assembly and separate the front frame.
50. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
51. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH
52. REMOVE STARTER ASSEMBLY
53. SEPARATE AUTOMATIC TRANSAXLE ASSEMBLY (TRANSAXLE)
54. SEPARATE MANUAL TRANSAXLE ASSEMBLY (M/T TRANSAXLE)
55. REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY (A/T TRANSAXLE)
a. Fix the crankshaft with SST (TMC made).
SST 09213-54015 (91651-60855), 09330-00021
b. Fix the crankshaft with SST (TMMK made).
SST 09960-10010 (09962-01000, 09963-01000)
c. Remove the 8 bolts, rear spacer, drive plate and front spacer.
56. REMOVE CLUTCH COVER ASSEMBLY (M/T TRANSAXLE)
57. REMOVE CLUTCH DISC ASSEMBLY (M/T TRANSAXLE)
58. REMOVE FLYWHEEL SUB-ASSEMBLY (M/T TRANSAXLE)
a. Fix the crankshaft with SST.
SST 09213-54015 (91651-60855), 09330-00021
b. Remove the 8 bolts, rear spacer, flywheel sub-assy.
59. INSTALL ENGINE STAND
60. REMOVE INTAKE MANIFOLD
a. Remove the 5 bolts, 2 nuts, intake manifold and gasket.
61. REMOVE VENTILATION HOSE
62. REMOVE VENTILATION HOSE NO. 2
63. REMOVE ENGINE WIRE
64. REMOVE INTAKE MANIFOLD INSULATOR NO. 1
65. REMOVE OIL LEVEL GAGE SUB-ASSEMBLY
66. REMOVE OIL LEVEL GAGE GUIDE
67. REMOVE MANIFOLD CONVERTER INSULATOR NO. 1
68. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
a. Remove the 3 bolts, 2 nuts No. 1 and No. 2 exhaust manifold stay.
b. Remove the 5 nuts, exhaust manifold converter and gasket.
69. REMOVE WATER INLET