Steps # 1 - # 28
WARNING:
^ Make sure the cooling system has cooled before opening. Hot coolant can cause serve burns.
^ Make sure all engine parts (e.g. exhaust components, engine block, etc.) have cooled before touching. Hot engine parts can cause serve burns.
NOTE:
^ When removing components such as tubes, hoses, and lines; cap the opening to prevent fluid from dripping/spilling.
^ If needed, additional details (line art images, system descriptions, etc.) for the removal and installation of components in this bulletin can be found in the appropriate Service Manual.
1. Write down all radio station settings.
2. If equipped, write down / record the following customer settings for the ATC (Automatic Temperature Control) system. (Refer to the Service Manual as needed):
^ Temperature Setting Trimmer
^ Foot Position Setting Trimmer
^ Inlet Port Memory Function (FRE and REC)
3. Disconnect the negative battery cable.
4. Remove the oil dip stick.
5. Remove the engine cover.
6. Remove the engine under cover.
7. Drain the engine coolant into a clean container as follows:
a. CAUTION: Make sure the cooling system has cooled.
b. Place a clean container under the radiator drain plug.
c. Remove the radiator drain plug.
d. Remove the radiator cap.
e. Store the coolant in a covered clean container (coolant will be reused).
8. Remove the front air duct.
^ Front air duct is held on with 3 bolts.
9. Remove the air cleaner case:
^ Remove 1 bolt.
^ Loosen clamp.
^ Disconnect transmission vent hose.
10. Attach an engine support bar to the transmission as shown.
^ Transverse Engine Support Bar 16-1725 from Tech-Mate can be used (or equivalent).
^ Use a bolt to attach the chain from the support bar hook to the top of the transmission as shown.
^ Adjust / tighten the hook and chain so the support bar is supporting the weight of the transmission.
NOTE:
Later in this procedure the front suspension member (engine cradle) will be removed / lowered from under the engine. The engine and transmission will be held in place by the engine mount at the front of the engine and the support bar that was just installed.
11. Remove the upper radiator hose:
^ Remove / reposition 2 clamps.
^ Remove bolt from center support.
12. Remove the nut for the front engine mount.
Reassembly torque:
103 Nm (11 kg-m, 76 ft-lb)
13. Disconnect the front engine mount vacuum hose.
14. Remove the 4 bolts holding the exhaust manifold heat shield LH.
Reassembly torque:
5.8 Nm (0.59 kg-m, 51 in-lb)
NOTE:
The heat shield will not be completely removed. Later in the procedure the loose heat shield will allow access to the catalyst mounting bolts.
15. Remove both front wheels.
Reassembly torque:
113 Nm (12 kg-m, 83 ft-lb)
Tighten bolts in three steps using a star pattern.
16. Remove the front fender protector side covers.
^ The right side is shown; remove both sides.
^ Each cover is held on with 6 clips.
17. Remove the front exhaust tube (see Figure 13):
^ Remove 2 nuts at center exhaust tube to front exhaust tube.
^ Remove 6 nuts / bolts at front exhaust tube to exhaust manifolds (both banks).
^ Remove nut and bolt for front exhaust tube stay. Remove 2 bolts for front exhaust tube bracket.
18. Remove the clamp nut and bolt for the lower ball joints.
^ Right side is shown; remove nut and bolt for both sides (left and right).
Reassembly torque:
63 Nm (6.4 kg-m, 46 ft-lb)
19. Separate the ball joints from the steering knuckles.
^ Right side is shown; separate ball joint from steering knuckle on both sides (left and right).
20. Remove the nuts from the upper end of the suspension connecting rods.
^ Right side is shown; remove nut from both sides (left and right).
Reassembly torque:
78.5 Nm (8.0 kg-m, 58 ft-lb)
21. Remove the cotter pin and nut for RH side tie rod end (see Figure 16).
22. Separate the RH side tie rod end from the steering knuckle.
23. Remove the 2 steering gear assembly mounting bolts (see Figure 16).
24. Attach elastic straps (or other suitable support) to each side of the steering gear assembly.
^ Right side is shown; attach a strap to both sides.
NOTE:
The support straps will hold the steering gear when the front suspension member is lowered.
25. Take the Power Steering (P/S) line loose from for the mounting points shown (1 bolt and 2 clips).
NOTE:
Do not remove the P/S line; just take it loose from the mounting points.
26. Remove bolt from lower toque rod.
Reassembly torque:
103 Nm (11 kg-m, 76 ft-lb)
27. Unclip the Power Steering (P/S) gear electrical harness from the front suspension member.
28. Remove the nut from the rear engine mount.
Reassembly torque:
103 Nm (11 kg-m, 76 ft-lb)