REPAIR INSTRUCTIONS
ON-VEHICLE SERVICE


AIR FILTER ASSEMBLY
Removal Procedure
- Disconnect the air intake tube and electrical connector from the air filter housing.
- Disconnect the intake tube clamp (1).
- Disconnect the air intake tube from the air filter housing (2).


- Remove the air filter, resonator, and snorkel assembly.
- Remove the snorkel bolt (1).
- Remove the air filter housing bolts (2).
- Remove the air filter housing, resonator, and snorkel assembly from the bracket (3).
-
- a. Bracket.


- Remove the air filter, resonator, and snorkel assembly separately.
- Remove the snorkel from the resonator pressing the part of hook (1).
-
- a. Hook.
- Remove the resonator from the air filter housing pressing the part of hook (2).
- b. Hook.


Installation Procedure
- Install in the reverse order of removal.
- Install the bolts.
Tighten
- Tighten the bolts to 7-9 N•m (62-80 lb-in) (a).


AIR FILTER ELEMENT
Removal Procedure
- Remove the air filter element.
- Remove the bolts (1).
- Remove the air filter upper housing with connecting manifold air temperature sensor with intake tube (2).
- Remove the air filter element (3).


Installation Procedure
- Install in the reverse order of removal.


POSITIVE CRANKCASE VENTILATION (PCV) HOSE AND VALVE
Removal Procedure
- Remove the positive crankcase ventilation (PCV) hose.
- Disconnect the hose from the intake tube (1).
- Disconnect the hose from the cylinder head cover (2).
- Disconnect the hose from the intake manifold lower (3).
- Remove the PCV hose with valve (4).


- Remove the PCV valve.
- Remove the PCV valve (1).
- Inspect the tube for crack, inflation or damage.
- Inspect the PCV valve orifice for damage. (When blowing up the valve using a mouth, air should be ventilated only in the direction of the arrow.)


Installation Procedure
- Install in the reverse order of removal.


INTAKE MANIFOLD
Removal Procedure
- Relieve the fuel system pressure. Refer to Section 1F, Engine Controls.
- Disconnect the negative battery cable.
- Remove the air filter, resonator, and snorkel assembly. Refer to "Air Filter Assembly" in this section.
- Disconnect the radiator lower hose and drain coolant (a). Refer to Section 1D, Engine Cooling.
- Remove the throttle body assembly (b). Refer to Section 1F, Engine Controls.
- Disconnect the PCV hose and valve. Refer to "PCV hose and Valve" in this section.


- Remove the fuel rail and injector (c). Refer to Section 1F, Engine Controls.
- Remove the EGR valve and solenoid. Refer to Section 1F, Engine Controls.


- Disconnect the cable, electrical connector and vacuum tube.
- Loosen the lock nut and disconnect the throttle cable (1).
- Disconnect the Manifold Absolute Pressure (MAP) sensor connector (2).
- Disconnect the evaporative emission canister solenoid connector (3).
- Disconnect the brake vacuum tube (4).
- Disconnect the MAP sensor vacuum tube (5).
- Disconnect the Intake Air Temperature (IAT) sensor connector (6).
- Remove the intake manifold main bracket bolts (only upper two).


- Remove the intake manifold subsidiary bracket.
- Remove the upper bolt (1).
- Remove the lower nut (2).
- Remove the subsidiary bracket (3).


- Remove the intake manifold.
- Remove the nuts (1).
- Remove the intake manifold from the cylinder head (2).


- Disconnect the intake manifold gasket.
- Disconnect the intake manifold gasket from the intake manifold (1).
Important : Carefully remove the gasket pulling the gasket upper position (a).
- Inspect the gasket for crack, hardening, inflation or damage.


Installation Procedure
- Install in the reverse order of removal.
- When installing the gasket on the intake manifold, install the gasket correctly.
- Install the intake manifold with nuts in numerical order.
Tighten
Tighten the nuts to 15-19 N•m (11-14 lb-ft).
Important : First of all, tighten the bracket nut and then tighten the remaining nuts.
-
- a. Bracket nut.


- Install the bolt/nut.
Tighten
- Tighten the intake manifold subsidiary bracket nut to 15- 19 N•m (11- 14 lb-ft) (a).
- Tighten the intake manifold subsidiary bracket bolt to 18-22 N•m (13- 16 lb-ft) (b).


EXHAUST MANIFOLD (TYPICAL)
Removal Procedure
Caution : Do not remove when the exhaust manifold parts are hot.
- Remove the air filter, resonator, and snorkel assembly. Refer to "Air Filter Assembly" in this section.
- Disconnect the ignition wire and oxygen sensor connector.
- Disconnect the ignition wires from the spark plugs (1).
- Disconnect the oxygen sensor connector (2).


- Remove the front exhaust pipe from the exhaust manifold.
- Remove the nuts (1).
- Remove the gasket and the pipe (2).


- Remove the exhaust manifold heat shield and exhaust manifold.
- Remove the bolts (1).
- Remove the exhaust manifold heat shield (2).
- Remove the nuts and bolts (3).
- Remove the exhaust manifold (4).
- Remove the gasket (5).
- Inspect the gasket for crack and damage.


Installation Procedure
- Install in the reverse order of removal.
- Install the seven exhaust manifold nuts and bolts and torque in the sequence shown.
Tighten
- Tighten the exhaust manifold nuts and bolts to 17-27 N•m (13-20 lb-ft) (a).
- Tighten the exhaust manifold heat shield bolts to 8-12 N•m (71-106 lb-in) (b).


- Install the front exhaust manifold pipe nuts.
Tighten
Tighten the front exhaust manifold pipe nuts to 25-35 N•m (18-25 lb-ft).


EXHAUST MANIFOLD (EURO III)
Removal Procedure
Caution : Do not remove when the exhaust manifold parts are hot.
- Remove the air filter, resonator, and snorkel assembly. Refer to "Air Filter Assembly" in this section.
- Disconnect the ignition wire and oxygen sensor (O2S) connector.
- Remove exhaust manifold heat shield.
Tighten
- Tighten the exhaust manifold heat shield bolts 8-12 N•m (71-106 lb-in).


- Remove the exhaust pipe from the pup-up catalytic converter.
Tighten
- Tighten the exhaust pipe-to-pup-up catalytic converter nuts 25-35 N•m (18-25 lb-ft).


- Remove the exhaust manifold with pup-up catalytic converter.
Tighten
- Tighten the exhaust manifold bolts and nuts to 17-27 N•m (13-20 lb-ft).
Installation Note
Tighten the bolts and nuts in the sequence shown.


- Remove the exhaust manifold from pup-up catalytic converter.
Tighten
- Tighten the exhaust manifold-to-catalytic converter bolts to 25-35 N•m (18-25 lb-ft).
- Installation should follow the removal procedure in the reverse order.


TIMING BELT
Removal Procedure
- Disconnect the negative battery cable.
- Remove the right headlamp. Refer to Section 9B, Lighting Systems.
- Remove the generator driver belt, A/C compressor driver belt and power steering driver belt, if equipped.
- Remove the timing belt front upper cover.
- Remove the bolts (1).
- Remove the cover (2).


- Remove the right wheel. Refer to Section 2E, Tires and Wheels.
- Align the mark on the crankshaft gear and camshaft gear.
- Using the crankshaft pulley bolt, rotate the crankshaft clockwise until the mark on the camshaft gear is aligned with the notch at the bottom of the rear timing belt cover (1).
-
- a. Mark on the camshaft gear.
- b. Notch at the bottom of the rear timing belt cover.


- Remove the crankshaft pulley.
- Remove the crankshaft pulley bolt (1).
- To remove the bolt, use a driver such as the picture shown (a).
- Remove the crankshaft pulley (2).


- Remove the oil level gauge guide tube and timing belt front lower cover.
- Remove the bolt (1).
- Remove the oil level gauge guide tube (2).
- Remove the bolts (3).
- Remove the timing belt front lower cover (4).


- Remove the timing belt.
- Loosen the timing belt tensioner bolt (1).
- Remove the timing belt (2).


Installation Procedure
- Install in the reverse order of removal.
Important : If the camshaft or crankshaft rotates in the process of installing the timing belt, perform the valve timing setting necessarily. Refer to "Valve Timing Check and Adjustment" in this section.
- Install the timing belt tensioner bolt.
Tighten
Tighten the timing belt tensioner bolt to 15-23 N•m (11-17 lb-ft).
Important : Turn the crankshaft twice to align the notch on the camshaft with the pointer on the rear cover and tighten the tensioner bolt.
-
- a. Notch on the camshaft.
- b. Pointer on the rear cover.


- Install the bolts.
Tighten
- Tighten the timing belt front lower cover bolts to 9-12 N•m (80-106 lb-in) (1).
- Tighten the oil level gauge guide tube bolt to 9-12 N•m (80-106 lb-in) (2).
- Tighten the timing belt front upper cover bolts to 9-12 N•m (80-106 lb-in) (3).


- Install the crankshaft pulley bolt.
- When installing the bolt, use the driver as shown in the picture (a).
Tighten
Tighten the crankshaft pulley bolt to 65-75 N•m (48-55 lb-ft).


OIL PAN
Removal Procedure
- Drain the engine oil from the engine crankcase.
- Remove the front exhaust pipe from the exhaust manifold.
- Remove the nuts (1).
- Remove the gasket (2).


- Remove the clutch housing lower plate.
- Remove the bolts (1).
- Remove the plate (2).


- Remove the oil pan.
- Remove the bolts and nuts (1).
- Remove the oil pan from the engine block (2).
- Clean the oil pan and engine block sealing surfaces.
- Clean the oil pan bolts.
- Clean the oil pan bolt holes in the engine block.


Installation Procedure
- Install in the reverse order of removal.
Important : Install the oil pan within 5 minutes after applying liquid gasket to the oil pan.
- Install the bolts and nuts.
Tighten
- Tighten the oil pan bolts and nuts to 9-12 N•m (80-106 lb-in) (a).
- Tighten the clutch housing lower plate bolts to 4-7 N•m (35-62 lb-in) (b).


- Install the front exhaust pipe nuts.
Tighten
Tighten the front exhaust pipe nuts to 25-35 N•m (18-25 lb-ft).


OIL PUMP
Removal Procedure
- Disconnect the negative battery cable.
- Remove the timing belt and timing belt tensioner. Refer to "Timing Belt" in this section.
- Remove the camshaft gear.
- Remove the bolt (1).
- Remove the camshaft gear from the camshaft (2).


- Remove the timing belt rear cover.
- Remove the bolts (1).
- Remove the timing belt rear cover (2).


- Remove the oil pan. Refer to "Oil Pan" in this section.
- Remove the oil pump strainer.
- Remove the bolts (1).
- Remove the oil pump strainer with oil seal (2).


- Remove the crankshaft gear and oil pump bolts.
- Remove the crankshaft gear from the crankshaft (1).
- Remove the oil pump bolts (2).


- Remove the A/C compressor bracket.
- Remove the A/C compressor bracket bolt (a).
- Remove the oil pump (1).
- Clean the oil pump and engine block gasket mating surfaces.
- Remove the oil seal from the oil pump (b).
- Inspect the oil seal for damage.


Installation Procedure
- Install in the reverse order of removal.
- Install a new oil pump gasket. If the crankshaft front oil seal is damaged, replace it with new oil seal.
- When installing the crankshaft front oil seal to the oil pump, make the oil seal groove faced toward the oil pump case contact surface as shown in the picture.
-
- a. Oil seal groove.
- b. Oil pump case contact surface.


- Install the oil pump strainer and bolts.
Tighten
Tighten the oil pump strainer bolts to 9-12 N•m (80-106 lb-in).


- Install the oil pump, oil pump cover bolts, and timing belt rear cover bolts.
-
- a. Oil pump cover bolts.
- b. Timing belt rear cover bolts.
Tighten
Tighten the oil pump cover bolts and the timing belt rear cover bolts to 9-12 N•m (80-106 lb-in).


- Install the camshaft gear and bolt.
Tighten
Tighten the camshaft gear bolt to 50-60 N•m (36-44 lb-ft).


DISTRIBUTOR CASE
Tools Required
DW 150-020 Distributor Case Nut Remover/Installer.
Removal Procedure
- Remove the distributor. Refer to Section 1E, Engine Electrical.
- Remove the surge tank cap (1). Disconnect the radiator lower hose and drain the coolant (2). Refer to Section 1D, Engine Cooling.


- Disconnect the electrical connectors.
- Disconnect the ignition wire clip (1).
- Disconnect the engine coolant temperature sensor connector (2).
- Disconnect the coolant temperature sensor connector (3).
- Disconnect the idle air control valve connector (4).
- Disconnect the throttle position sensor connector (5).


- Disconnect the tubes.
- Disconnect the coolant inlet tube (1).
- Disconnect the coolant outlet tube (2).
- Disconnect the vacuum tube (3).
- Disconnect the radiator upper hose (4).
- Disconnect the heat core inlet hose (5).


- Remove the intake manifold main bracket.
- Remove the bolts (1).
- Remove the nut (2).
- Remove the bolt and electrical clip (3).
- Remove the main bracket (4).


- Remove the distributor.
- Remove the bolt (1).
- Remove the nuts (2).
Important : Using the distributor case nut remover/installer DW 150-020, remove distributor lower nuts.
- Remove the distributor and gasket (3).


- Remove the coolant temperature sensors, thermostat and housing from the distributor case.
- Remove the engine coolant temperature sensor (1).
- Remove the coolant temperature sensor (2).
- Remove the bolts (3).
- Remove the thermostat housing (4).
- Remove the thermostat with the gasket.


Installation Procedure
- Install in the reverse order of removal.
- If the distributor housing gasket is damaged, replace it with new one.
- Install the nut and bolts.
Tighten
- Tighten the distributor housing nuts and bolt 9-12 N•m (80-106 lb-in) (a).
- Tighten the intake manifold main bracket bolts (10M) to 9-12 N•m (80-106 lb-in) (b).
- Tighten the intake manifold main bracket bolt (12M) to 18-22 N•m (13-16 lb-ft) (c).
- Tighten the intake manifold main bracket nut to 9-12 N•m (80-106 lb-in) (d).


CYLINDER HEAD AND GASKET
Removal Procedure
- Relieve the fuel system pressure. Refer to Section 1F, Engine Controls.
- Disconnect the negative battery cable.
- Remove the air filter, resonator, and the snorkel assembly. Refer to "Air Filter Assembly" in this section.
- Remove the surge tank cap (a). Disconnect the radiator lower hose and drain the coolant (b). Refer to Section 1D, Engine Cooling.


- Disconnect the fuel injector wire connectors and fuel line inlet hose.
-
- d. Fuel injector wire connectors.
- e. Fuel line inlet hose.


- Disconnect the cable, electrical connectors and tubes.
- Disconnect the throttle cable (1).
- Disconnect the MAP sensor connector (2).
- Disconnect the canister solenoid connector (3).
- Disconnect the brake booster vacuum hose (4).
- Disconnect the MAP sensor vacuum hose (5).


- Disconnect the ignition wires and electrical connectors.
- Disconnect the ignition wires from the spark plugs and distributor cap (1).
- Disconnect the engine coolant temperature sensor connector (2).
- Disconnect the coolant temperature sensor connector (3).
- Disconnect the oxygen sensor connector (4).
- Disconnect the idle air control valve connector (5).
- Disconnect the throttle position sensor connector (6).


- Disconnect the fuel injector wire connector (7).
- Disconnect the distributor optical sensor connector.
- Remove the EGR solenoid.


- Disconnect the coolant hose and vacuum tube.
- Disconnect the throttle body coolant outlet hose (1).
- Disconnect the evaporative emission canister vacuum tube (2).
- Disconnect the radiator upper hose from the thermostat housing (3).
- Disconnect the heat core inlet hose from the thermostat housing (4).
- Disconnect the EGR solenoid vacuum tube.


- Remove the timing belt. Refer to "Timing Belt" in this section.
- Remove the camshaft gear.
- Remove the bolt (1).
- Remove the camshaft gear from the camshaft (2).


- Remove the timing belt rear cover and front exhaust pipe.
- Remove the bolts (1).
- Remove the rear cover from the cylinder head and block (2).
- Remove the nuts (3).
- Remove the gasket (4).


- Disconnect the MAP sensor vacuum tube and PCV valve and hose.
- Disconnect the MAP sensor vacuum tube (1).
- Disconnect the PCV hose and valve (2).
- Remove the oil filler cap (3).


- Remove the cylinder head cover.
- Remove the cylinder head cover hexagon bolts (1).
- Remove the cylinder head cover with gasket (2).


- Remove the cylinder head assembly.
- Gradually loosen all of the cylinder head bolts in the sequence shown.
- Remove the cylinder head bolts (1).
- Remove the cylinder head assembly from the engine block, with the intake/exhaust manifold, throttle body, distributor housing and cylinder head gasket (2).
- Inspect the cylinder head gasket for damaged.
- Clean the gasket surfaces of the cylinder head and the engine block.
- Clean the cylinder head bolts.




Installation Procedure
- Install in the reverse order of removal.
- Install new cylinder head gasket.
- Install the cylinder head bolts in the sequence shown.
Tighten
Tighten the cylinder head bolts to 85-90 N•m (63-66 lb-ft).


- Install the cylinder head cover hexagon bolts.
Tighten
Tighten the cylinder head cover hexagon bolts to 9-12 N•m (80-106 lb-in).


- Install the bolts and nuts.
Tighten
- Tighten the front exhaust pipe nuts to 25-35 N•m (18-25 lb-ft) (1).
- Tighten the timing belt rear cover bolts to 9-12 N•m (80-106 lb-in) (2).


- Tighten the camshaft gear bolt to 50-60 N•m (36-44 lb-ft) (3).


ENGINE MOUNT DAMPING BLOCK
Tools Required
DW 110-021 Engine Assembly Support Fixture.
Removal Procedure
- Install the engine assembly support fixture DW 110-021.
- Remove the cowl panel weatherstrip.
- Remove the exhaust manifold heat shield.
- Position the engine assembly support fixture DW 110-021 on the cowl panel and the front upper panel on the center.


- Tighten the engine fixture joint with a bolt after removing exhaust manifold bolt.
-
- a. Exhaust manifold bolt.
- Remove the coolant surge tank. Refer to Section 1D, Engine Cooling.
- Remove the right headlamp. Refer to Section 9B, Lighting Systems.
- Remove the intermediate bracket nuts.
- Remove the intermediate bracket nut from the lower vehicle (1).
- Remove the intermediate bracket nut from the upper vehicle (2).


- Remove the engine mount damping block assembly with the intermediate bracket attached.
- Remove the engine mount damping block bolts (1).
Important : Loosen the bolts adjusting the engine assembly support fixture up and down slightly.
Notice : If the bolts are loosened without adjusting the engine assembly support fixture, they could be damaged.
- Remove the engine mount damping block assembly from the wheel house and engine mount upper bracket (2).


- Remove the engine mount damping block from the intermediate bracket.
- Vice the intermediate bracket (1).
- Remove the intermediate bracket bolt (2).
- Remove the engine mount damping block from the intermediate bracket (3).
- Inspect the damping block for the crack, hardening or damaged.
- a. Damping block.


Installation Procedure
- Install in the reverse order of removal.
- Install the bolts.
Tighten
- Tighten the intermediate bracket bolt to 72-88 N•m (53-65 lb-ft) (1).
- Tighten the engine mount damping block bolts to 45-55 N•m (33-41 lb-ft) (2).


- Install the nuts.
Tighten
Tighten the lower/upper engine mount intermediate bracket nuts to 60-70 N•m (44-52 lb-ft) (3, 4).


ENGINE MOUNT FRONT DAMPING BUSH
Removal Procedure
- Remove the exhaust manifold. Refer to Exhaust Manifold in this section.
- Remove the stabilizer. Refer to Section 2C, Front Suspension.
- Remove the bolts and nut.
- Remove the front damping bush bolt and nut (bracket side) (1).
- Remove the front damping bush bolts (crossmem-ber side) (2).


- Remove the front bracket bolts (engine block side) (3).


- Remove the engine mount front damping bush assembly and the front bracket.
- Remove the front bracket and the damping bush as shown in the picture.
-
- a. Damping bush.
- b. Front bracket.


- Inspect the engine mount damping bush assembly for crack and damage (a).


Installation Procedure
- Install in the reverse order of removal.
- Install the bolts and nut.
Tighten
Tighten the front bracket bolts (cylinder block side) to 35-41 N•m (25-30 lb-ft) (1).
Tighten the front damping bush bolt (crossmember side) to 35-41 N•m (25-30 lb-ft) (2).
Tighten the front damping bush bolts (crossmem-ber side) to 45-55 N•m (33-41 lb-ft) (3).
Tighten the front damping bush bolt and nut (bracket side) to 68-83 N•m (50-62 lb-ft) (4).




ENGINE ASSEMBLY
Tools Required
DW 110-041 Engine & Transaxle Assembly Support Remover/Installer.
Removal Procedure
- Discharge the air conditioning (A/C) system, if equipped.
- Drain the power steering oil, if equipped.
- Relieve the fuel system pressure. Refer to Section 1F, Engine Controls.


- Disconnect the negative battery cable.
- Remove the air filter, resonator with snorkel assembly (a). Refer to "Air Filter Assembly" in this section. Remove Engine Ignition System Ignition Coil, if equiped.
- Disconnect the radiator lower hose and drain the coolant (b). Refer to Section 1D, Engine Cooling.
- Disconnect the fuel line inlet hose and the fuel injector wire connectors from the fuel rail (c, d).


- Remove the canister and disconnect the cables, the electrical connector, and the vacuum hose.
- Disconnect the throttle cable (2).
- Disconnect the Manifold Absolute Pressure (MAP) sensor connector (3).
- Disconnect the canister solenoid connector (4).
- Disconnect the brake booster vacuum hose (5).
- Disconnect the MAP sensor vacuum hose (6).
- Disconnect the evaporative emission canister vacuum hose.
- Disconnect Intake Air Temperature (IAT) sensor connector.


- Remove the distributor. Refer to Section 1E, Engine Electrical.
- Disconnect the electrical connectors and hoses.
- Disconnect the engine coolant temperature sensor connector (1).
- Disconnect the coolant temperature sensor connector (2).
- Disconnect the oxygen sensor connector (3).
- Disconnect the idle air control valve connector (4).
- Disconnect the throttle position sensor connector (5).
- Disconnect camshaft position (CMP) sensor connector and crankshaft position (CKP) sensor connector.
- Disconnect the heat core inlet hose.
- Disconnect the throttle body coolant outlet hose.


- Remove the coolant surge tank (b).


- Remove the coolant fan.
- Disconnect the electrical connector (1).
- Loosen the bolts (2).
- Take out the coolant fan assembly as shown in the picture (3).


- Remove the radiator hose.
- Disconnect and remove the radiator upper hose (1).
- Disconnect and remove the radiator surge tank hose (2).
- Disconnect and remove the radiator lower hose (3).


- Remove the radiator.
- Loosen the bolts (1).
- Remove the radiator mounting brackets (2).
- Take out the radiator as shown in the picture (3).


- Disconnect the connectors, the pipes and the hoses. (If equipped with the air conditioning (A/C) system and the power steering).
- Disconnect the power steering pressure sensor connector (1).
- Disconnect the hose from the power steering pump (2).
- Disconnect the pipe from the power steering pump (3).
- Disconnect the air conditioning low and high pressure pipes (4).
- Disconnect the power steering hose.


- Disconnect the select and shift cable.
- Remove the cable pin (1).
- Remove the washer (2).
- Disconnect the select and shift cable (3).
- Remove the E-ring (4).


- Remove the engine electrical wire bending strap.
- Disconnect the transaxle case ground connection line and the backup lamp switch electrical connector.
- Loosen the ground connection line bolt (1).
- Disconnect the ground connection line (2).
- Disconnect the backup lamp switch electrical connector (3).
- Disconnect the hydraulic pressure pump assembly and the gear position sensor electrical connector. (If equipped with auto clutch). Refer to Section 5D, Auto Clutch.


- Remove the transaxle under cover.
- Loosen the bolts (1).
- Remove the cover (2).


- Drain the transaxle oil.
- Remove the oil drain plug to drain oil.
- Disconnect the clutch cable.
- Loosen the cable adjusting nut (1).
- Disconnect the cable from the wire clip (2).
- Disconnect the cable from the transaxle mount hole (3).


- Disconnect the speedometer cable.
- Loosen the nut (1).
- Disconnect the cable (2).
- Disconnect the vehicle speed sensor electrical connector, if equipped.


- Remove the front exhaust pipe.
- Loosen the nuts (1).
- Remove the gasket and disconnect the pipe (2).
- Loosen the nuts (3).
- Remove the front exhaust pipe (4).


- Disconnect the electrical connector.
- Disconnect oil pressure switch electrical connector (1).
- Disconnect the generator +B terminal (2).
- Disconnect the generator electrical connector (3).
- Disconnect the starter electrical connector (4).
- Disconnect the electrical wire strap (5).


- Disconnect the surge tank coolant return hose and the heater outlet hose.
- Surge tank coolant return hose (1).
- Heater outlet hose (2).


- Remove both of the front wheels. Refer to Section 2E, Tires and Wheels.
- Remove the control arm and the tie rod end. Refer to Section 2C, Front Suspension.
-
- a. Control arm stud bolt.
- b. Tie rod end castellated nut.


- Remove the left/right front longitudinal member and stabilizer bar. Refer to Section 2C, Front Suspension.
-
- a. Stabilizer bar.
- b. Front longitudinal member.


- Remove the left/right drive axle.
- Loosen the caulking nut. Refer to Section 2C, Front Suspension.
- Remove the drive axle (wheel side) (1).
- Insert a driver between the transaxle case and the drive axle joint case (2).
- Remove the drive axle (differential side) as shown in the picture (3).
Notice : Removing the drive axle, be careful lest the differential oil seal is damaged.


- Remove the engine mount front bracket and the damping bush assembly.
- Remove the bolt and nut (a).
- Remove the engine mount front bracket and the damping bush assembly (b, c).


- Remove the crossmember. Refer to Section 2C, Front Suspension.
- Remove the right crossmember (a).
- Remove the left crossmember (b).


- Loosen the engine mount intermediate bracket nut.
-
- a. Engine mount intermediate bracket nut.
- Support the oil pan with the engine & transaxle assembly support remover/installer DW 110-041.
-
- b. Engine & transaxle assembly support remover/ installer DW 110-041.
- Loosen the engine mount intermediate bracket nut.
-
- c. Engine mount intermediate bracket nut.
Important : Before loosening the engine mount intermediate bracket nut, oil pan should be supported by the engine & transaxle assembly support remover/installer DW 110-041.




- Remove the engine mount reaction rod.
- Loosen the bolt and nut from the engine mount lower bracket (1).
- Loosen the bolt from the body bracket (2).
- Remove the engine mount reaction rod (3).


- Loosen the transaxle mount bolts and remove the mount.
-
- a. Transaxle mount bolts.


- Remove the engine/transaxle assembly.
- Lower the special tool slowly (1).
- Remove the engine/transaxle assembly (2).


- Remove the transaxle from the engine/transaxle assembly. Refer to Section 5B, Five-Speed Manual Transaxle.
- Remove some parts to be equipped with the engine assembly. Refer to "Unit Repair" in this section.


Installation Procedure
- Install in the reverse order of removal.
- Install the bolts and nuts.
Tighten
- Tighten the transaxle mount bolt to 45-55 N•m (33-41 lb-ft) (a).
- Tighten the reaction rod bolt (body bracket side) to 68-83 N•m (50-61 lb-ft) (b).
- Tighten the reaction rod bolt/nut (lower bracket side) to 68-83 N•m (50-61 lb-ft) (c).


- Tighten the engine mount intermediate bracket lower nut to 60-70 N•m (44-52 lb-ft) (d).
- Tighten the engine mount intermediate bracket upper nut to 60-70 N•m (44-52 lb-ft) (e).


- Tighten the right crossmember rear side bolts to 17-27 N•m (13-20 lb-ft) (f).
- Tighten the left crossmember rear side bolts to 17-27 N•m (13-20 lb-ft) (g).


- Tighten the front bracket bolt (engine block side) to 35-41 N•m (25-30 lb-ft) (h).


- Tighten the front damping bush bolt (crossmember side) to 35-41 N•m (25-30 lb-ft) (i).
- Tighten two front damping bush bolts (crossmem-ber side) to 45-55 N•m (33-41 lb-ft) (i).
- Tighten the front damping bush bolt and nut to 68-83 N•m (50-62 lb-ft) (j).


- Tighten the stabilizer bar castellated nut to 40-50 N•m (30-36 lb-ft) (k).
- Tighten the stabilizer bar mounting bolt to 33-53 N•m (24-39 lb-ft) (l).


- Tighten the front longitudinal member bolt to 10-14 N•m (7-10.5 lb-ft) (m).
- Tighten the front longitudinal member nut to 60-80 N•m (44-59 lb-ft) (n).


- Tighten the control arm stud nut to 50-70 N•m (36-52 lb-ft) (o).
- Tighten the tie rod end castellated nut to 35- 55 N•m (25-41 lb-ft) (p).


- Tighten the front exhaust pipe nuts (muffer pipe side) to 25-35 N•m (18-25 lb-ft) (q).
- Tighten the front exhaust pipe nuts (exhaust manifold side) to 25-35 N•m (18-25 lb-ft) (r).


- Tighten the transaxle under-cover bolts to 35-55 N•m (25-41 lb-ft) (s).


- Tighten the power steering pump pressure pipe nut to 36-50 N•m (26-36 lb-ft) (t).
- Tighten the power steering pump pressure pipe fitting to 21-35 N•m (15-25 lb-ft) (u).


- Tighten the air conditioning low/high pressure pipe bolts to 23 N•m (17 lb-ft) (v).


- Tighten the radiator bolt to 4-5 N•m (35-44 lb-in) (w).
- Tighten the cooling fan bolt to 4-5 N•m (35-44 lb-in) (x).
- Tighten the distributor bolt to 10-16 N•m (7-12 lb-ft) (y).


- Tighten the snorkel bolt to 7-9 N•m (62-80 lb-in) (a).
- Check the air conditioning low/high pressure pipe O-ring seal, the select/shift cable pin/washer/Ering, the tie rod end joint castellated nut cotter pin, stabilizer castellated nut cotter pin for loss.
- Refill transaxle oil, power steering oil and coolant after finishing all installation procedures.
- Check if the fuel inlet hose is connected with the fuel rail correctly.
- Check if the electrical connectors are connected correctly.
- Connect the negative battery cable.
- Reset the engine control module (ECM). Refer to Section 1F, Diagnosis.
- Start the engine and check the engine for the normal operation.
- Recharge the air conditioning gas and check the oil and coolant level.
- Check the vacuum hose, the coolant hose, the exhaust pipe, the air conditioning/power steering pipe and hose for leakage.
Check if the electrical connectors are connected correctly.
 |
|
 |
|
© Copyright General Motors Daewoo Europe. All rights reserved |