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T8B52C15
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Cylinder Head and Gasket

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Drain the engine coolant. Refer to Section 1D, Engine Cooling.
  3. Relieve the fuel pressure. Refer to Section 1F1, Engine Ccontrols.
  4. Remove the cylinder Head cover. Refer to “Cylinder Head Cover" in this section.

    5. T8B52C17
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  5. Remove the timing chain cover. Refer to “Timing Chain System" in this section.

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  6. Remove the camshaft. Refer to “Camshaft” in this section.

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  7. Remove the intake manifold. Refer to “Intake Manifold” in this section.

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  8. Remove the exhaust manifold. Refer to “Exhaust Manifold" in this section.

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  9. Remove the cylinder head bolts.
  10. Remove the cylinder head with the gasket.

Cleaning

  1. Clean the cylinder head sealing surface.
  2. Clean the cylinder block sealing surface.
  3. Clean the cylinder head cover bolts.
  4. Clean the cylinder head cover bolt holes.

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Installation Procedure

  1. Install the cylinder head assembly and the NEW gasket.
  2. Tighten the cylinder head bolts.

    3. Tighten
    Cylinder Head Bolts : 22 N•m + 82°


    T8B52C14
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  3. Install the exhaust manifold. Refer to “Exhaust Manifold" in this section.

    4. T8B52C13
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  4. Install the intake manifold. Refer to “Intake Manifold" in this section.

    5. T8B52C18
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  5. Install the camshaft. Refer to “Camshaft" in this section.

    6. T8B52C18
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  6. Install the timing chain. Refer to “Timing Chain System" in this section.

    7. T8B52C15
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  7. Install the cylinder Head cover. Refer to “Cylinder Head Cover" in this section.
  8. Refill the engine cooling system. Refer to Section 1D, Engine Cooling.
  9. Connect the negative battery cable.

T8B52G03
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Oil Pan

Removal Procedure

    Caution : If the oil pan is deformed when removing it, do not use it and use a new oil pan.

  1. Disconnect the negative battery cable.
  2. Drain the engine oil.
  3. Remove the front exhaust pipe. Refer to Section 1G, Engine Exhaust.

    4. T8B52C16
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  4. Remove the oil pan retaining bolts.
  5. Remove the oil pan.
  6. Remove the gasket between the oil pan and the sealing surface of the engine block.

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Installation Procedure

  1. Apply the liquid gasket to the oil pan.
  2. Install the oil pan to the engine block and tighten the Oil Pan Retaining Bolts.

    3. Tighten
    Oil Pan Retaining Bolts : 10.5 N•m (7.7 lb-ft).


    T8B52G03
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  3. Install the front exhaust pipe. Refer to Section 1G, Engine Exhaust
  4. Refill the engine oil.

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Oil Pump

Tools Required

EN-49072 Installer-Crankshaft Front Seal

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the cylinder head cover. Refer to “Cylinder Head Cover" in this section.
  3. Remove the front exhaust pipe. Refer to Section 1G, Engine Exhaust.

    4. T8B52C37
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  4. Remove the oil pan. Refer to “Oil Pan" in this section.
  5. Remove the timing chain cover. Refer to “Timing Chain System" in this section.
  6. Remove the gasket between the oil pan and the sealing surface of the engine block.

    7. T8B52C39
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  7. Remove the oil pump retaining bolts from the timing chain cover.

T8B52C39
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Installation Procedure

  1. Tighten the oil pump retaining bolts from the timing chain cover and install the oil pump.

    2. Tighten
    Oil Pump Cover Bolts : 10 N•m (7.4 lb-ft).

  2. Install the timing chain cover. Refer to “Timing Chain System" in this section.

    3. T8B52C39
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    Notice : 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.

  3. Install the crankshaft front oil seal using the installer(EN-49072).

    4. T8B52C37
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  4. Install the oil pan. Refer to “Oil Pan" in this section.
  5. Install the cylinder head cover. Refer to “Cylinder Head Cover" in this section.

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  6. Install the spark plug cable cover.
  7. Connect the negative battery cable.

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Engine Mount

Tools Required

DW110-060 Fixture-Engine Assembly Support

Removal Procedure

  1. Remove the air cleaner assembly. Refer to “Air Cleaner Assembly" in this section.
  2. Support the engine assembly using the engine assembly support fixture DW110-060.

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  3. Remove the engine mount bracket retaining bolts/nuts.

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  4. Remove the engine mount retaining bolts.
  5. Remove the engine mount assembly.

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Installation Procedure

  1. Install the engine mount assembly.
  2. Tighten the engine mount retaining bolts.

    3. Tighten
    Engine Mount Retaining Bolts : 55 N•m (40.5 lb-ft).


    S7B31C07
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  3. Tighten the engine mount bracket retaining bolts/nuts.

    4. Tighten
    Engine Mount Bracket Retaining Bolts/Nuts : 65 N•m (47.9 lb-ft).

  4. Remove the engine assembly support fixture DW110-060.
  5. Install the air cleaner assembly. Refer to “Air Cleaner Assembly" in this section.

T8B52C35
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Engine Assembly

Tools Required

DW010-010 Engine & Transaxle Assembly Support Remover/Installer

Removal Procedure

  1. Discharge the air condition(A/C) system, if equipped.
  2. Drain the power steering oil, if equipped.
  3. Drain the engine coolant. Refer to Section 1D, Engine Cooling.
  4. Remove the battery and battery tray. Refer to Section 1E, Engine Electrical.
  5. Remove the air cleaner assembly. Refer to “Air Cleaner Assembly" in this section.

    6. T8B52C63
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  6. Disconnect the radiator inlet and outlet hose.
  7. Disconnect the heater core inlet and outlet hose.

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  8. Remove the power steering hose from the power steering pump. Refer to Section 6B, Power Steering Pump.
  9. Remove the A/C compressor hose from the compressor. Refer to Section 7B, Manual Control Heating, Ventilation and Air Conditioning System.

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  10. Disconnect the accelerator cable.
  11. Disconnect the TPS connector.
  12. Disconnect the IACV connector.
  13. Disconnect the A/C pressure sensor connector.
  14. Disconnect the power steering oil pressure switch cable.

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  15. Disconnect the coolant temperature sensor connector.
  16. Disconnect the EGR valve connector.
  17. Disconnect the camshaft sensor connector.
  18. Disconnect the ignition coil connector.
  19. Disconnect the oxygen sensor connector.
  20. Disconnect the crank position sensor connector.

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  21. Disconnect the injector main connector.
  22. Disconnect the canister solenoid connector.
  23. Disconnect the VGIS solenoid connector.
  24. Disconnect the starter connector. Refer to Section 1E, Engine Electrical
  25. Disconnect the alternator connector. Refer to Section 1E, Engine Electrical

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  26. Remove the clutch cable and connectors. Refer to Section 5B, Five–Speed Manual Transaxle, if manual–transaxle.
  27. Remove the shift control cable from the auto–transaxle. Refer to Section 5A, AISIN Automatic Transaxle, if auto–transaxle.

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  28. Support the engine assembly using the engine assembly support fixture DW010-010.

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  29. Remove the engine mount bracket. Refer to “Engine Mount” in this section.
  30. Remove the transaxle mount bracket.

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  31. Remove the transaxle rear mount.

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  32. Remove the engine assembly.
  33. Remove the transmission from the engine assembly.

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  34. Remove the flywheel(manual transmission) or flexible plate(auto transmission).

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Installation Procedure

  1. Install the flywheel(manual transmission) or flexible plate(auto transmission).

    2. Tighten
    Flywheel/Flexible Plate Bolts : 45 N•m (33.2 lb-ft).


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  2. Install the transmission to the engine assembly.

    3. Tighten
    Transmission Assembly Blots (M/T & A/T) : 60 N•m (44.2 lb-ft).


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  3. Support the engine assembly using the engine assembly support fixture DW010-010.

    4. S7B31C07
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  4. Install the engine mount bracket. Refer to “Engine Mount” in this section.
  5. Install the transaxle mount bracket. Refer to “Engine Mount” in this section.

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  6. Install the transaxle rear mount.

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  7. Connect the clutch cable and connectors. Refer to Section 5B, Five–Speed Manual Transaxle, if manual–transaxle.
  8. Connect the shift control cable from the auto–transaxle. Refer to Section 5A, AISIN Automatic Transaxle, if auto–transaxle.

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  9. Connect the injector main connector.
  10. Connect the canister solenoid connector.
  11. Connect the VGIS solenoid connector.
  12. Connect the starter connector. Refer to Section 1E, Engine Electrical
  13. Connect the alternator connector. Refer to Section 1E, Engine Electrical

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  14. Connect the coolant temperature sensor connector.
  15. Connect the EGR valve connector.
  16. Connect the camshaft sensor connector.
  17. Connect the ignition coil connector.
  18. Connect the oxygen sensor connector.
  19. Connect the crank position sensor connector.

    20. T3D11C11
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  20. Connect the accelerator cable.
  21. Connect the TPS connector.
  22. Connect the IACV connector.
  23. Connect the A/C pressure sensor connector.
  24. Connect the power steering oil pressure switch cable.

    25. T8B58B05
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  25. Install the power steering hose from the power steering pump. Refer to Section 6B, Power Steering Pump.
  26. Install the A/C compressor hose from the compressor. Refer to Section 7B, Manual Control Heating, Ventilation and Air Conditioning System.

    27. T8B52C63
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  27. Connect the radiator inlet and outlet hose.
  28. Connect the heater core inlet and outlet hose.

    29. T8B52C35
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  29. Refill the engine coolant system. Refer to Section 1D, Engine Cooling.
  30. Install the battery and battery tray. Refer to Section 1E, Engine Electrical
  31. Install the air cleaner assembly. Refer to "Air Cleaner Assembly" in this section.


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