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REPAIR INSTRUCTIONS

ON-VEHICLE SERVICE



D12B5011
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AIR FILTER ASSEMBLY

Removal Procedure

  1. Disconnect the air intake tube and electrical connector from the air filter housing.



  2. Display graphicTranslations of text in graphics


  3. Remove the air filter, resonator, and snorkel assembly.
  4. a. Bracket.


    D12B5031
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  5. Remove the air filter, resonator, and snorkel assembly separately.
  6. a. Hook.
    b. Hook.


D12B5041
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Installation Procedure

  1. Install in the reverse order of removal.
  2. Install the bolts.
  3. Tighten



D12B5051
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AIR FILTER ELEMENT

Removal Procedure

  1. Remove the air filter element.


D12B5061
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Installation Procedure

  1. Install in the reverse order of removal.


D102B507
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POSITIVE CRANKCASE VENTILATION (PCV) HOSE AND VALVE

Removal Procedure

  1. Remove the positive crankcase ventilation (PCV) hose.


  2. D102B508
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  3. Remove the PCV valve.


D12B507A
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Installation Procedure

  1. Install in the reverse order of removal.


D12B5091
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INTAKE MANIFOLD

Removal Procedure

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


  7. D12B5101
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  8. Remove the fuel rail and injector (c). Refer to Section 1F, Engine Controls.
  9. Remove the EGR valve and solenoid. Refer to Section 1F, Engine Controls.


  10. D12B5111
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  11. Disconnect the cable, electrical connector and vacuum tube.


  12. D102B512
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  13. Remove the intake manifold subsidiary bracket.


  14. D102B513
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  15. Remove the intake manifold.


  16. D102B514
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  17. Disconnect the intake manifold gasket.
  18. Important : Carefully remove the gasket pulling the gasket upper position (a).



D12B515A
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Installation Procedure

  1. Install in the reverse order of removal.
  2. Install the intake manifold with nuts in numerical order.
  3. 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.


    D12B516A
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  4. Install the bolt/nut.
  5. Tighten



D102B517
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EXHAUST MANIFOLD (TYPICAL)

Removal Procedure

    Caution : Do not remove when the exhaust manifold parts are hot.

  1. Remove the air filter, resonator, and snorkel assembly. Refer to "Air Filter Assembly" in this section.
  2. Disconnect the ignition wire and oxygen sensor connector.


  3. D102G501
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  4. Remove the front exhaust pipe from the exhaust manifold.


  5. D102B518
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  6. Remove the exhaust manifold heat shield and exhaust manifold.


D12B519A
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Installation Procedure

  1. Install in the reverse order of removal.
  2. Install the seven exhaust manifold nuts and bolts and torque in the sequence shown.
  3. Tighten



    D12B520A
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  4. Install the front exhaust manifold pipe nuts.
  5. Tighten
    Tighten the front exhaust manifold pipe nuts to 25-35 N•m (18-25 lb-ft).



MAA1B010
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EXHAUST MANIFOLD (EURO III)

Removal Procedure

    Caution : Do not remove when the exhaust manifold parts are hot.

  1. Remove the air filter, resonator, and snorkel assembly. Refer to "Air Filter Assembly" in this section.
  2. Disconnect the ignition wire and oxygen sensor (O2S) connector.
  3. Remove exhaust manifold heat shield.
  4. Tighten



    MAA1B020
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  5. Remove the exhaust pipe from the pup-up catalytic converter.
  6. Tighten



    MAA1B030
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  7. Remove the exhaust manifold with pup-up catalytic converter.
  8. Tighten

    Installation Note
    Tighten the bolts and nuts in the sequence shown.


    MAA1B040
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  9. Remove the exhaust manifold from pup-up catalytic converter.
  10. Tighten

  11. Installation should follow the removal procedure in the reverse order.


D102B521
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TIMING BELT

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the right headlamp. Refer to Section 9B, Lighting Systems.
  3. Remove the generator driver belt, A/C compressor driver belt and power steering driver belt, if equipped.
  4. Remove the timing belt front upper cover.


  5. D102B522
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  6. Remove the right wheel. Refer to Section 2E, Tires and Wheels.
  7. Align the mark on the crankshaft gear and camshaft gear.
  8. a. Mark on the camshaft gear.
    b. Notch at the bottom of the rear timing belt cover.


    D102B523
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  9. Remove the crankshaft pulley.


  10. D102B524
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  11. Remove the oil level gauge guide tube and timing belt front lower cover.


  12. D102B525
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  13. Remove the timing belt.


D12B526A
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Installation Procedure

  1. Install in the reverse order of removal.
  2. 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.

  3. Install the timing belt tensioner bolt.
  4. 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.



    D12B527A
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  5. Install the bolts.
  6. Tighten



    D12B528A
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  7. Install the crankshaft pulley bolt.
  8. Tighten
    Tighten the crankshaft pulley bolt to 65-75 N•m (48-55 lb-ft).



D102G501
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OIL PAN

Removal Procedure

  1. Drain the engine oil from the engine crankcase.
  2. Remove the front exhaust pipe from the exhaust manifold.


  3. D102B529
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  4. Remove the clutch housing lower plate.


  5. D102B530
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  6. Remove the oil pan.


D12B531A
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Installation Procedure

  1. Install in the reverse order of removal.
  2. Important : Install the oil pan within 5 minutes after applying liquid gasket to the oil pan.

  3. Install the bolts and nuts.
  4. Tighten



    D12B520A
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  5. Install the front exhaust pipe nuts.
  6. Tighten
    Tighten the front exhaust pipe nuts to 25-35 N•m (18-25 lb-ft).



D12B532
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OIL PUMP

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the timing belt and timing belt tensioner. Refer to "Timing Belt" in this section.
  3. Remove the camshaft gear.


  4. D102B533
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  5. Remove the timing belt rear cover.


  6. D102B534
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  7. Remove the oil pan. Refer to "Oil Pan" in this section.
  8. Remove the oil pump strainer.


  9. D102B535
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  10. Remove the crankshaft gear and oil pump bolts.


  11. D102B536
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  12. Remove the A/C compressor bracket.
  13. Remove the oil pump (1).


D102B537
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Installation Procedure

  1. Install in the reverse order of removal.
  2. Install a new oil pump gasket. If the crankshaft front oil seal is damaged, replace it with new oil seal.
  3. 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.
  4. a. Oil seal groove.
    b. Oil pump case contact surface.


    D102B538A
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  5. Install the oil pump strainer and bolts.
  6. Tighten
    Tighten the oil pump strainer bolts to 9-12 N•m (80-106 lb-in).



    D12B539A
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  7. Install the oil pump, oil pump cover bolts, and timing belt rear cover bolts.
  8. 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).



    D12B540A
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  9. Install the camshaft gear and bolt.
  10. Tighten
    Tighten the camshaft gear bolt to 50-60 N•m (36-44 lb-ft).



D102D501
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DISTRIBUTOR CASE

Tools Required

DW 150-020 Distributor Case Nut Remover/Installer.

Removal Procedure

  1. Remove the distributor. Refer to Section 1E, Engine Electrical.
  2. Remove the surge tank cap (1). Disconnect the radiator lower hose and drain the coolant (2). Refer to Section 1D, Engine Cooling.


  3. D102B542
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  4. Disconnect the electrical connectors.


  5. D102B543
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  6. Disconnect the tubes.


  7. D102B544
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  8. Remove the intake manifold main bracket.


  9. D102B545
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  10. Remove the distributor.
  11. Important : Using the distributor case nut remover/installer DW 150-020, remove distributor lower nuts.



    D102B546
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  12. Remove the coolant temperature sensors, thermostat and housing from the distributor case.


D12B547A
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Installation Procedure

  1. Install in the reverse order of removal.
  2. Install the nut and bolts.
  3. Tighten



D102D5
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CYLINDER HEAD AND GASKET

Removal Procedure

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


  5. D12B5481
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  6. Disconnect the fuel injector wire connectors and fuel line inlet hose.
  7. d. Fuel injector wire connectors.
    e. Fuel line inlet hose.


    D12B5111
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  8. Disconnect the cable, electrical connectors and tubes.


  9. D102B549
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  10. Disconnect the ignition wires and electrical connectors.


  11. D102B550
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    D102B551
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  12. Disconnect the coolant hose and vacuum tube.


  13. D102B532
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  14. Remove the timing belt. Refer to "Timing Belt" in this section.
  15. Remove the camshaft gear.


  16. D102B552
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  17. Remove the timing belt rear cover and front exhaust pipe.


  18. D102B553
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  19. Disconnect the MAP sensor vacuum tube and PCV valve and hose.


  20. D102B554
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  21. Remove the cylinder head cover.


  22. D102B555
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  23. Remove the cylinder head assembly.


  24. D102B556
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D12B557A
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Installation Procedure

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



    D12B558A
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  5. Install the cylinder head cover hexagon bolts.
  6. Tighten
    Tighten the cylinder head cover hexagon bolts to 9-12 N•m (80-106 lb-in).



    D12B559A
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  7. Install the bolts and nuts.
  8. Tighten



    D12B560A
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D13B5041
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ENGINE MOUNT DAMPING BLOCK

Tools Required

DW 110-021 Engine Assembly Support Fixture.

Removal Procedure

  1. Install the engine assembly support fixture DW 110-021.


  2. D102B561
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    a. Exhaust manifold bolt.
  3. Remove the coolant surge tank. Refer to Section 1D, Engine Cooling.
  4. Remove the right headlamp. Refer to Section 9B, Lighting Systems.
  5. Remove the intermediate bracket nuts.


  6. D102B562
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  7. Remove the engine mount damping block assembly with the intermediate bracket attached.
  8. 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.



    D102B563
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  9. Remove the engine mount damping block from the intermediate bracket.
  10. a. Damping block.


D12B564A
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Installation Procedure

  1. Install in the reverse order of removal.
  2. Install the bolts.
  3. Tighten



    D12B565A
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  4. Install the nuts.
  5. Tighten
    Tighten the lower/upper engine mount intermediate bracket nuts to 60-70 N•m (44-52 lb-ft) (3, 4).



D102B597
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ENGINE MOUNT FRONT DAMPING BUSH

Removal Procedure

  1. Remove the exhaust manifold. Refer to Exhaust Manifold in this section.
  2. Remove the stabilizer. Refer to Section 2C, Front Suspension.
  3. Remove the bolts and nut.


  4. D102B598
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    D102B599
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  5. Remove the engine mount front damping bush assembly and the front bracket.
  6. a. Damping bush.
    b. Front bracket.


    D102B600
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    1. Inspect the engine mount damping bush assembly for crack and damage (a).


D12B601A
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Installation Procedure

  1. Install in the reverse order of removal.
  2. Install the bolts and nut.
  3. 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).



    D12B602A
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D12B5021
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ENGINE ASSEMBLY

Tools Required

DW 110-041 Engine & Transaxle Assembly Support Remover/Installer.

Removal Procedure

  1. Relieve the fuel system pressure. Refer to Section 1F, Engine Controls.


  2. D12B5671
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  3. Disconnect the negative battery cable.
  4. 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.
  5. Disconnect the radiator lower hose and drain the coolant (b). Refer to Section 1D, Engine Cooling.
  6. Disconnect the fuel line inlet hose and the fuel injector wire connectors from the fuel rail (c, d).


  7. D12B5111
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  8. Remove the canister and disconnect the cables, the electrical connector, and the vacuum hose.


  9. D102B569
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  10. Remove the distributor. Refer to Section 1E, Engine Electrical.
  11. Disconnect the electrical connectors and hoses.


  12. D12B5701
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  13. Remove the coolant surge tank (b).


  14. D102D506
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  15. Remove the coolant fan.


  16. D12B5711
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  17. Remove the radiator hose.


  18. D12D5091
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  19. Remove the radiator.


  20. MAA1B050
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    D103B501
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  21. Disconnect the select and shift cable.


  22. D103B502
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  23. Remove the engine electrical wire bending strap.
  24. Disconnect the transaxle case ground connection line and the backup lamp switch electrical connector.


  25. D103B505
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  26. Remove the transaxle under cover.


  27. D103B506
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  28. Drain the transaxle oil.
  29. Disconnect the clutch cable.


  30. D103B507
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  31. Disconnect the speedometer cable.


  32. D102B573
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  33. Remove the front exhaust pipe.


  34. D12B5741
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  35. Disconnect the electrical connector.


  36. D102B575
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  37. Disconnect the surge tank coolant return hose and the heater outlet hose.


  38. D104B501
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  39. Remove both of the front wheels. Refer to Section 2E, Tires and Wheels.
  40. Remove the control arm and the tie rod end. Refer to Section 2C, Front Suspension.
  41. a. Control arm stud bolt.
    b. Tie rod end castellated nut.


    D102B575
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  42. Remove the left/right front longitudinal member and stabilizer bar. Refer to Section 2C, Front Suspension.
  43. a. Stabilizer bar.
    b. Front longitudinal member.


    D102B577
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  44. Remove the left/right drive axle.
  45. Notice : Removing the drive axle, be careful lest the differential oil seal is damaged.



    D102B603
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  46. Remove the engine mount front bracket and the damping bush assembly.


  47. D102B578
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  48. Remove the crossmember. Refer to Section 2C, Front Suspension.


  49. D102B579
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  50. Loosen the engine mount intermediate bracket nut.
  51. a. Engine mount intermediate bracket nut.
  52. Support the oil pan with the engine & transaxle assembly support remover/installer DW 110-041.
  53. b. Engine & transaxle assembly support remover/ installer DW 110-041.
  54. Loosen the engine mount intermediate bracket nut.
  55. 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.



    D102B580
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    D102B581
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  56. Remove the engine mount reaction rod.


  57. D12B5821
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  58. Loosen the transaxle mount bolts and remove the mount.
  59. a. Transaxle mount bolts.


    D102B583
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  60. Remove the engine/transaxle assembly.


  61. D102B584
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  62. Remove the transaxle from the engine/transaxle assembly. Refer to Section 5B, Five-Speed Manual Transaxle.
  63. Remove some parts to be equipped with the engine assembly. Refer to "Unit Repair" in this section.


D12B5851
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Installation Procedure

  1. Install in the reverse order of removal.
  2. Install the bolts and nuts.
  3. Tighten



    D12B586A
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    D12B587A
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    D12B604A
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    D12B605A
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    D12B588A
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    D12B589A
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    D12B590A
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    D12B591A
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    D12B592A
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    D12B593A
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    D12B594A
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    D12B595A
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    D12B5041
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  4. 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.
  5. Refill transaxle oil, power steering oil and coolant after finishing all installation procedures.
  6. Check if the fuel inlet hose is connected with the fuel rail correctly.
  7. Check if the electrical connectors are connected correctly.
  8. Connect the negative battery cable.
  9. Reset the engine control module (ECM). Refer to Section 1F, Diagnosis.
  10. Start the engine and check the engine for the normal operation.
  11. Recharge the air conditioning gas and check the oil and coolant level.
  12. Check the vacuum hose, the coolant hose, the exhaust pipe, the air conditioning/power steering pipe and hose for leakage.
  13. Check if the electrical connectors are connected correctly.


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