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Section 2  Engine Components Replacement

1. Avoid gasoline ejection when work.

2. Drain the coolant to empty.

3. Remove air filter assembly with hose. See  (Figure 23)

4. Remove battery

5. Remove fuel delivery pipe sub-assembly

6. Disconnect water hoses, disconnect heater outlet hose 

from A/C hose.

7. Loose nut, remove accelerator control cable

8. Remove throttle body assembly

9. Remove power steering pump reservoir assembly

10. Remove front exhaust pipe assembly

11. Remove steering gear boot

12. Seperate steering column assembly. See (Figure 24)

13. Remove front wheel hub nut

14. Disconnect front wheel vehicle speed sensor (with ABS)

15. Detach steering tie rod ball stud pin assembly

16. Detach front lower swing arm sub-assembly

17. Detach front propeller assembly. See (Figure 25)

Detach front propeller from the shaft hub with plastic hammer.

18. Disconnect transmission shift cable or gear shift level assembly

19. Disconnect clutch cylinder assembly or disconnect clutch cable

20. Detach engine assembly and transaxle

(a) Hoisting engine ;

(b) Remove 3 bolts. Detach the right engine mounting bracket. See (Figure 26) ;

(c) Remove 1 bolt. Detach the left engine mounting bracket;

(d) Remove 1 bolt. Detach the rear engine mounting bracket;

(e) Remove engine and transaxle and put them on the pallet;

(f) Jack up the boday.

Figure 23

Figure 24

Figure 25

Figure 26

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21. Remove radiator assembly

22. Remove engine V-belt

23. Remove No. 1 V- belt (A/C compressor to crankshaft pulley)

24. Remove generator assembly

25. Remove A/C compressor

26. Remove compressor installing No. 1 bracket. Remove 4 bolts and compressor installing No.

1 bracket.

27. Remove starter assembly

28. Remove power steering pump V- belt

29. Detach power steering pump assembly

30. Remove power steering pump, adjust the bracket

31. Detach manual transaxle assembly (Separate automatic transaxle assembly)

32. Detach clutch cover panel assembly.

33. Detach clutch pressure plate assembly.

34. Detach flywheel sub-assembly.

35. Remove engine rear end cover.

36. Remove injector assembly and remove intake manifold.

Remove 2 bolts and intake manifold support and remove 7 bolts,

2 nuts, intake manifold and gasket. See (Figure 27).

37. Remove knock sensor

38. Remove water temperature gauge sensor

39. Remove crankshaft position sensor

40. Remove engine oil pressure switch

41. Remove water inlet hose housing

42. Remove water outlet hose joint

43. Detach exhaust manifold. See (Figure 28)

44. Remove engion oil filter sub-assembly

45. Remove ignition coil and high voltage cable

46. Install engine sub-assembly

47. Install ignition coil and high voltage cable

48. Install engine oil filter sub-assembly

49. Install exhaust manifold

(a) Install new gasket and exhaust manifold stay with 

5 nuts, Torque: 34N. m

(b) Install exhaust manifold stay with two bolts.

Torque: 59N. m

(c) Install upper heat shield with 4 bolts. Torque: 17N. m

Figure 27

Figure 28

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50. Install water outlet hose joint. See (Figure 29, 30)

Figure 29 

51. Install water inlet hose housing. See (Figure 31, 32)

Figure 31

 Figure 32

52. Install engine oil pressure switch

53. Install crankshaft position sensor

Torque: 9, 3N. m

54. Install water temperature gauge and water temperature sensor

Torque: 15N. m

55. Install knock sensor

Torque: 44N. M

56. Install intake manifold. See (Figure 33)

Install the intake manifold with new gasket with 7 bolts and 2

nuts. Uniformly tighten bolts and nuts in several time.

57. Install injector assembly

58. Install rear end cover

59. Install flywheel sub-assembly. See (Figure 34)

(a) Install flywheel to crankshaft.

(b)Install and uniformly tighten and connect bolt as shown in the 

 figure. Torque: 78N. m

60. Install clutch assembly

61. Install flywheel and ring gear. See (Figure 35)

(a)Install the oil thrower, it’s chamfer side on crankshaft in

the axie direction.

(b) Install flywheel and ring gear on crankshaft.

Figure 33

Figure 34

Figure 30

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(c) Install and uniformly tighten connecting bolt in the sequence shown in the figure.

 Torque: 64N. m

62. Install manual transaxle assembly

63. Install starter assembly

64. Install power steering pump bracket

65. Install power steering pump adjusting bracket with 2 bolts.

66. Connect power steering pump assembly

67. Install engine assembly and transaxle

68. Connect left, right, front and rear lower suspension arm sub-assembly

69. Connect left and right tie rod ball stud pin assembly

70. Connect left, right and front vehicle speed sensor (with ABS)

71. Install left & right nuts on the front shaft hub

72. Install front exhaust pipe assembly

73. Connect steering shaft assembly and steering column hole cover. See (Figure 36)

74. Connect wire harness

75. Install belt adjusting bracket of A/C compressor

76. Connect A/C compressor

77. Install generator assembly

78. Install A/C compressor to crankshaft pulleyV-belt

79. Install generator belt

80. Install engine assembly with transaxle

81. Install radiator assembly

82. Install throttle body assembly

83. Install fuel delivery pipe sub-assembly

84. Install battery

85. Install air filter assembly with hose

86. Install front wheel

87. Fill engine oil

88. Fill coolant

89. Check engine oil for leakage

90. Check engine coolant for leakage

91. Check fuel for leakage

92. Check idle and ignition timing

93. Check CO/HC

94. Check and adjust front wheel alignment

95. Check ABS vehicle speed sensor signal

Figure 35

Figure 36