Removal
TOOLS REQUIRED- SA9105E Engine Support Bar Assembly
- SA91112T Axle Seal Protector
- SA9132S Lower Control Arm Ball Stud Separator
REMOVAL
CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON HOIST. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.
1. Position vehicle on hoist.
2. Remove air cleaner and duct assembly.
3. Disconnect negative battery cable from battery.
4. Disconnect positive battery cable from battery.
5. Remove hold-down retaining nut and screws, and lift off battery hold-down retainer.
6. Lift battery out of vehicle, and place in a safe location.
IMPORTANT: The PCM J1 (black 80-way) harness connector does not need to be disconnected.
7. Disconnect PCM J2 (black 28-way) harness connector by moving locking device outward toward fender.
8. Remove PCM attachment bolts and move PCM out of way.
9. Remove battery tray bolts and tray.
9.1 One bolt is located in the fender well.
10. Remove transaxle strut-to-midrail bracket fastener.
11. Loosen transaxle strut to transaxle bracket fastener and flip transaxle strut out of the way.
12. Disconnect all electrical connectors from transaxle.
12.1 Back-up lamp switch.
12.2 Vehicle speed sensor.
12.3 Two ground terminals from top two clutch housing bolts.
13. Remove vent tube retaining clip if equipped.
14. Remove top two clutch housing-to-engine bolts. (Automatic shown, manual similar.)
IMPORTANT: Note which spark plug wire is removed from which coil tower. The spark plug wires must be connected to the correct coil towers.
15. Disconnect spark plug wires from coil towers.
16. Disconnect electrical connectors at the electronic ignition module.
17. Remove bolts from electronic ignition module. Remove electronic ignition module.
18. Remove shifter cables from shift arms and from clutch housing. Use care not to damage cable boot.
NOTICE: Removal of the hydraulic damper with a power tool prior to removal of the actuator could result in breaking off the hydraulic line.
IMPORTANT: Prior to removing the slave cylinder from the clutch housing, make sure that the clutch hydraulic system has sufficient fluid.
19. Rotate clutch slave cylinder 1/4 turn counter-clockwise while pushing into clutch housing. Remove cylinder from housing.
20. Remove two clutch hydraulic dampener to clutch housing fasteners. Wire the actuator cylinder and the dampener to the upper radiator hose.
21. Wire the radiator to the upper radiator support to hold the radiator in place when frame is removed.
IMPORTANT: The two cross bars on the engine support have two settings, one for the SOHC (L24) (1) and one for the DOHC (LLO) (2) engine. The setting locations are marked on the bars as shown.
22. Install Engine Support Bar Assembly SA9IOSE.
22.1 Place engine support bar in vehicle as shown. Place the support bar feet on the outer edge of the shock tower.
22.2 Connect bar hooks to engine support brackets.
22.3 Position stabilizer foot on engine block to the right of the engine oil dipstick.
22.4 Adjust hooks and stabilizer to remove looseness.
CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON HOIST. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.
23. Raise vehicle and drain transaxle fluid.
24. Remove front wheels.
25. Remove left and right front inner fender splash shields.
26. Remove front engine splash shield from vehicle.
27. Remove engine strut frame bracket-to-frame fasteners.
28. Remove transaxle mount-to-frame fastener.
29. Remove front exhaust pipe-to-manifold fasteners.
30. Remove front exhaust pipe-to-catalytic converter nuts.
31. Remove exhaust pipe support bracket-to-exhaust pipe fasteners.
32. Remove front exhaust pipe from vehicle.
33. Remove steering gear to frame fasteners. (Power steering gear shown, manual steering gear similar.)
34. Support steering gear with safety wire.
35. Remove brake pipe bracket push pin at rear of frame.
36. Remove engine to transaxle stiffening brace bolts and remove brace.
37. Remove dust cover to clutch housing bolts and remove dust cover.
38. Remove cotter pin from lower ball joints and discard. Loosen nut and back off until top of nut is even with top of threads.
39. Repeat for opposite side.
NOTICE: On ABS equipped vehicles, the outer CV joint has a speed sensor ring. Using the incorrect tool or procedure to separate the control arm from the knuckle can damage the ring, resulting in a loss of ABS operation.
NOTICE: Do not attempt to separate the joint using a wedge type tool because the boot may be damaged.
IMPORTANT: It will be necessary to pull down on lower control arm to remove castle nut.
40. Separate ball joint from lower control arm using Lower Control Arm Ball Stud Separator SA9132S and remove nut.
41. Repeat for opposite side.
NOTICE: Do not allow screwdriver to contact axle seal or damage to the seal may occur.
42. Separate left side axle from transaxle using a large screwdriver or appropriate pry bar.
43. Remove axle only part way and install Axle Seal Protector SA91112T. Use seal protector that was previously used or open up protector at split line and install around axle and into seal. This will protect the seal from being cut by the shaft spline.
44. Separate right side axle from intermediate shaft.
45. On DOHC (LL0) vehicles, remove intake bracket to intake manifold bolt.
46. Remove intake bracket to intermediate shaft support bolt, and remove support bracket.
47. Remove two intermediate shaft to engine block bolts.
48. Carefully slide intermediate shaft out of transaxle.
49. Use the powertrain support dolly and two 4 inch x 4 inch x 36 inch pieces of lumber to support the frame on the dolly.
50. Remove the four frame-to-body bolts. Carefully lower the frame from the vehicle with the powertrain support dolly.
51. Support transaxle securely with jack.
52. Remove two bottom clutch housing to engine bolts, and install guide bolt into bottom rear clutch housing bolt hole.
53. Separate transaxle from engine and lower transaxle.