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T3D11B69
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Oil Pump

  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 with the camshaft gear bolt.

    4. T3D11B70
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  4. Remove the timing belt rear cover bolts.
  5. Remove the timing belt rear cover.

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

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  9. Remove the crankshaft gear from the crankshaft.
  10. Remove the oil pump bolts.

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  11. Remove the A/C compressor/ Power steering pump bracket bolt.
  12. Remove the A/C compressor/ Power steering pump bracket.
  13. Remove the oil pump.
  14. Clean the oil pump and engine block gasket mating surfaces.
  15. Remove the oil seal from the oil pump.
  16. Inspect the oil seal for damage.

T3D11B42
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Installation Procedure

  1. Install a new oil pump gasket to the oil pump.
  2. Install the oil pump to the engine block with the bolts.

    3. Tighten
    Tighten the oil pump bolts to 10.5 N•m ( 93 lb-in).


    T3D11B43
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  3. Install the oil pump strainer.
  4. Install the oil pump strainer bolts.

    5. Tighten
    Tighten the oil pump strainer bolts to 10.5 N•m (93 lb-in)

  5. Install the oil pan. Refer to "Oil Pan" in this section.

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  6. Install the rear timing belt cover.
  7. Install the rear timing belt cover bolts.

    8. Tighten
    Tighten the rear timing belt cover bolts to 10.5 N•m (93 lb-in).

  8. Install the timing belt. Refer to "Timing Belt" in this section.

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  9. Install the camshaft gear and bolt.

    10. Tighten
    Tighten the camshaft gear bolt to 55 N•m (41 lb-ft).

  10. Install the air filter housing. Refer to "Air Filter Housing" in this section.

T3D11B73
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Oil Pan

  1. Drain the engine oil from the engine crankcase.
  2. Remove the front exhaust pipe. Refer to Section 1G, Engine Exhaust.
  3. Remove the flywheel or flexible plate inspection cover bolts.
  4. Remove the flywheel or flexible plate inspection cover.

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  5. Remove the oil pan retaining bolts and the nuts.
  6. Remove the oil pan from the engine block.
  7. Clean the oil pan sealing surfaces.
  8. Clean the oil pan retaining bolts and the nuts.
  9. Clean the oil pan retaining bolts holes in the engine.

T3D11B46
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Installation Procedure

    Important : Install the oil pan within 5 minutes after applying liquid gasket to the oil pan.

  1. Install the oil pan to the engine block.
  2. Install the oil pan retaining bolts and the nuts.

    3. Tighten
    Tighten the oil pan retaining bolts and the nuts to 10 N•m ( 89 lb-in).


    T3D11B47
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  3. Install the flywheel or flexible plate inspection cover.
  4. Install the flywheel or flexible plate inspection cover bolts.

    5. Tighten
    Tighten the flywheel inspection cover bolts to 5.5 N•m ( 49 lb-in ).


    T3D11B48
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  5. Install the front exhaust pipe nuts.

    6. Tighten
    Tighten the front exhaust pipe nuts to 30 N•m (22 lb-ft).


T3D11B62
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Engine Mount

Tools Required

DW 110-060 Engine Assembly Support Fixture

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Support the engine assembly using the engine assembly support fixture DW 110-060.
  3. Remove the air filter housing bolts.

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  4. Remove the air filter housing.
  5. Remove the intermediate bracket bolt.
  6. Remove the engine mount damping block bolts.
  7. Remove the intermediate bracket nuts.
  8. Remove the engine mount.

T3D11B49
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Installation Procedure

  1. Install the engine mount.
  2. Install intermediate bracket bolt.

    3. Tighten
    Tighten the intermediate bracket bolt to 55 N•m (41 lb-ft).


    T3D11B50
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  3. Install the engine mount damping block bolts.

    4. Tighten
    Tighten the engine mount damping block bolts to 50 N•m (37 lb-ft).

  4. Install the engine mount intermediate bracket nut.

    5. Tighten
    Tighten the engine mount intermediate bracket nut to 65 N•m ( 44 lb-ft).

  5. Install the air filter housing.
  6. Remove the engine support fixture.
  7. Connect the negative battery cable.

T3D11B51
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Intake Manifold

Removal Procedure

  1. Remove the fuel pump fuse.
  2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.
  3. Disconnect the negative battery cable.
  4. Remove the air filter housing.

    5. T3D11B52
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  5. Remove the fuel rail. Refer to Section 1F, Engine Controls.
  6. Disconnect the A/C pressure sensor connector.
  7. Disconnect the power steering pump pressure sensor connector.

    8. T3D11B78
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  8. Disconnect the throttle cable bracket with the bolt.
  9. Disconnect the manifold absolute pressure (MAP) sensor connector.
  10. Remove the brake booster vacuum hose at the intake manifold.

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  11. Remove the EGR Pipe and valve.
  12. Remove the engine wiring harness from the intake manifold.
  13. Remove the intake manifold retaining bolts and the nuts in the sequence shown.

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  14. Remove the intake manifold.

    15. T3D11B81
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  15. Remove the intake manifold gasket.
  16. Remove the intake manifold subsidiary bracket bolts.
  17. Remove the intake manifold subsidiary bracket.

T3D11B53
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Installation Procedure

  1. Install in the reverse order of removal.
  2. Install the intake manifold gasket.
  3. Install the intake manifold subsidiary bracket.
  4. Install the intake manifold subsidiary bracket.

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  5. Install the intake manifold retaining nuts and the bolts in the sequence shown.

    6. Tighten
    Tighten the intake manifold retaining nuts and bolts to 17 N•m (13 lb-ft).


T5B11B12
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Exhaust Manifold

Removal Procedure

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

  1. Remove the exhaust manifold heat shield bolts.
  2. Remove the exhaust manifold heat shield.
  3. Disconnect the oxygen sensor electrical connector.

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  4. Remove the exhaust manifold lower flange nuts.

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  5. Remove the front exhaust pipe bracket bolts.

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  6. Remove the oxygen sensor. Refer to Section 1F, Engine Controls.
  7. Remove the exhaust manifold nuts and the bolts.
  8. Remove the exhaust manifold.
  9. Remove the exhaust manifold gasket.
  10. Clean the sealing surfaces of the exhaust manifold and cylinder head.

T5B11B14
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Installation Procedure

  1. Install the exhaust manifold gasket.
  2. Install the exhaust manifold.
  3. Install the exhaust manifold bolts and the nuts.

    4. Tighten
    Tighten the exhaust manifold bolts and the nuts to 22 N•m ( 16 lb-ft ).


    T5B11B15
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  4. Install the front exhaust pipe bracket bolts and catalytic converter lower flange nuts.

    5. Tighten


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  5. Install the oxygen sensor connector.
  6. Install the oxygen sensor. Refer to Section 1F, Engine Controls.
  7. Install the heat shield.
  8. Install the heat shield bolts.

    9. Tighten
    Tighten the exhaust manifold heat shield bolts to 10 N•m (89 lb-in).


T3D11B84
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Engine

Removal Procedure

    Important : On vehicle equipped with a manual transaxle, the manual transaxle must be removed before engine removal. Refer to Section 5B, Five-Speed Manual Transaxle.

  1. Remove the fuel pump fuse.
  2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.
  3. Drain the engine oil.
  4. Disconnect the negative battery.
  5. Disconnect and separate the battery positive cable.
  6. Discharge the air conditioning (A/C) system, if equipped. Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System.
  7. Disconnect the electrical connector at the engine control module (ECM).
  8. Remove the battery. Refer to Section 1E, Engine Electrical.
  9. Remove the coolant surge tank.
  10. Disconnect the fuse box cover.
  11. Disconnect the electrical connector at the fuse box.
  12. Remove the fuse box bolts and the nut.
  13. Remove the fuse box.

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  14. Drain the engine coolant. Refer to Section 1D, Engine Cooling.
  15. Disconnect the upper radiator hose.
  16. Disconnect the lower radiator hose.
  17. Disconnect the heater inlet/outlet hose.

    18. T3D11B87
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  18. Disconnect the negative battery cable from the vehicle frame.

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  19. Disconnect the main connector from the engine wiring harness.

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  20. Remove the air filter housing.
  21. Disconnect the fuel line at the fuel rail.
  22. Disconnect the vacuum lines at the evaporative (EVAP) emission canister purge.
  23. Disconnect the A/C pressure transducer connector.
  24. Disconnect the power steering hose.

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  25. Remove the A/C compressor hose assembly retaining bolt.
  26. Disconnect the A/C compressor hose assembly from the compressor.
  27. Disconnect the electrical connector from the A/C compressor.

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  28. Disconnect the oxygen sensor at the cooling fans.
  29. Disconnect the gear shift control cable. Refer to Section 5B, Five-Speed Manual Transaxle.
  30. Remove the under cover.

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  31. Disconnect the clutch cable. Refer to Section 5C, Clutch.
  32. Remove the right front wheel. Refer to Section 2E, Tires and Wheels.
  33. Disconnect the tie rod end and control arm from the knuckle.

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  34. Remove the drive axle from the transaxle. Refer to Section 3B, Manual Transaxle Drive Axle.
  35. Remove the front exhaust pipe. Refer to Section 1G, Engine Exhaust.
  36. Remove the rear mounting bracket bolts.
  37. Remove the rear mounting bracket. Refer to Section 5A, Transaxle Assembly.

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  38. Support the engine assembly using the engine assembly support fixture.

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  39. Remove the engine mount. Refer to "Engine Mount" in this section.
  40. Remove the transaxle mount. Refer to Section 5A, Transaxle Assembly.
  41. Separate the engine block from the transaxle.
  42. Remove the engine.
  43. Transfer any necessary parts.

T3D11B60
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Installation Procedure

  1. Install the engine into the engine compartment.
  2. Align the transaxle alignment pins to the transaxle.
  3. Install the transaxle bell housing. Refer to Section 5A, Transaxle Assembly.
  4. Install the engine mount. Refer to "Engine Mount" in this section.
  5. Install the transaxle mount. Refer to Section 5A, Transaxle Assembly.

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  6. Remove the engine lifting device.
  7. Install the catalytic converter. Refer to Section 1G, Engine Exhaust.
  8. Install the front exhaust pipe. Refer to Section 1G, Engine Exhaust.
  9. Install the power steering pump pressure hose. Refer to Section 6A, Power Steering System.
  10. Install the power steering pump pressure hose fitting. Refer to Section 6A, Power Steering System.

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  11. Install the air conditioning low/high pressure pipe. Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System.
  12. Install the air filter housing.
  13. Check the air conditioning low/high pressure pipe O-ring seal, the select/shift cable pin/washer/E-ring, the tie rod end joint castellated nut cotter pin, stabilizer castellated nut cotter pin for loss.
  14. Refill transaxle oil, power steering oil and coolant after finishing all installation procedure.

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  15. Check if the fuel hose is connected with fuel rail correctly.
  16. Connect the negative battery.
  17. Reset the engine control module (ECM). Refer to Section 1F, Diagnosis.
  18. Start the engine and check the engine for the normal operation.

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  19. Recharge the air conditioning gas and check the oil and coolant level.
  20. 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 and connected correctly.


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