REMOVAL & INSTALLATION
The radio may have a coded theft protection circuit. Make sure you have the code before disconnecting the battery, removing the radio fuse, or removing the radio.
1.8L, 2.2L and 2.3L Engines
See Figures 1 through 7
- Disconnect negative cable at the battery.
- Raise and safely support the vehicle. Drain the oil and remove the lower splash panel.
- Detach the Heated Oxygen (HO 2 S) sensor connector.
- Remove the nuts and bolts connecting exhaust pipe A to the catalytic converter. Discard the gasket and the lock nuts.
- Remove and discard the nuts attaching exhaust pipe A to the exhaust hanger.
- If applicable, remove the mounting bolts from the center beam. Remove the center beam from the subframe.
- Remove and discard the lock nuts attaching exhaust pipe A to the exhaust manifold, then remove exhaust pipe A from the vehicle. discard the exhaust gaskets.
- Loosen the oil pan bolts in a crisscross pattern. To remove the oil pan, lightly tap the corners of the oil pan with a rubber or plastic faced mallet. Clean off all the old gasket material.
- Apply liquid gasket to the oil pan mating surface where the oil pump and the right side cover meet the engine block.
- Install the oil pan gasket to the oil pan.
- Install the oil pan, then finger tighten the center and end mounting nuts and bolts in the proper sequence.
See Figures 8 and 9
- Tighten the oil pan mounting nuts and bolts starting from the center bolt next to the oil drain plug (bolt No. 1) and work clockwise, tightening the bolts in three steps. Tighten the bolts to 10 ft. lbs. (14 Nm).
Excessive tightening can cause distortion of the oil pan gasket and oil leakage.
- Install the oil drain plug with a new gasket, tighten the plug to 33 ft. lbs. (44 Nm).
- Install exhaust pipe A using new gaskets and lock nuts. Tighten the nuts attaching the exhaust pipe to the exhaust manifold to 40 ft. lbs. (54 Nm). Tighten the nuts attaching the exhaust pipe to the catalytic converter and the exhaust pipe hanger to 16 ft. lbs. (22 Nm).
- Attach the heated O 2 S sensor connector.
- Install the lower splash panel, then lower the vehicle.
- Fill the engine with oil.
- Connect the negative battery cable and enter the radio security code.
- Run the engine and check for leaks.
- Turn off engine and check the oil level. Top off the oil level if necessary.
- Shift the manual transaxle to 1st gear or automatic transaxle to the P position.
- Disconnect the negative battery cable.
- Remove the air cleaner housing.
- Raise and safely support the vehicle and remove the front wheels.
- Drain the engine oil and coolant.
- Remove the strut forks.
- Remove the lower ball joint nut. Use a ball joint remover to disconnect the ball joint from the control arm.
- Carefully pry the inner CV-joints out of their sockets. Wrap them in plastic to keep them clean. Do not let the driveshafts hang by the outer CV-joint.
- Drain the differential oil.
- Disconnect the differential oil cooler hoses.
- Install the a suitable shaft puller tool, and disengage the extension shaft from the differential.
- Remove the side splash shield.
- Attach a chain hoist to the lifting hooks and take up the engine's weight.
- Remove the transaxle side mount and bracket.
- Unbolt and remove the left front engine mount bracket.
- Remove the power steering speed sensor from the differential. Do not disconnect the hoses.
- Remove the differential mounting bolts and the 26mm shim. Remove the differential from the vehicle.
- Unbolt the intermediate shaft bearing housing from the oil pan and pull the intermediate shaft assembly from the oil pan pipe.
- Remove the A/C compressor, then its mounting bracket. Leave the A/C lines connected to the compressor. Support the compressor with a piece of wire to move it out of the work area and take the weight off the A/C lines.
- Remove the set plate that holds the oil pan inner pipe from the right side of the engine.
- Unbolt the oil pan and remove it from the vehicle.
- Clean the oil pan and engine block mating surfaces. Apply an even bead of liquid gasket to the engine block sealing surface. Apply some liquid gasket to the inner threads of the bolt holes.
- Install the oil pan and tighten the bolts in the correct sequence to 16-17 ft. lbs. (22-24 Nm), as shown in the accompanying figure.
See Figure 10
- Install new O-rings on the oil pan inner pipe. Install the pipe and tighten the set plate bolts to 9 ft. lbs. (12 Nm).
- Install the differential, making sure the original shim is in the proper position. Tighten the bolts to 54 ft. lbs. (75 Nm). Connect the cooling hoses.
- Install new set and snaprings on the extension shaft. Coat the splines and their mating surfaces with high temperature grease. Thread the special installation tool into the transaxle case to install the extension shaft.
- Pack the extension shaft cavity with high temperature grease and install the 33mm sealing bolt. Tighten the bolt to 58 ft. lbs. (80 Nm) and install the secondary cover.
- Install the intermediate shaft, tighten the bolts to 16 ft. lbs. (22 Nm).
- Install the left front engine mount bracket and tighten the bolts to 40 ft. lbs. (54 Nm). Tighten the mounting bolt to 54 ft. lbs. (74 Nm).
- Install the transaxle side bracket and mount. Tighten the bracket mounting bolts and through bolt to 40 ft. lbs. (54 Nm). Install new mount bolts and tighten them to 47 ft. lbs. (64 Nm).
- Install the A/C compressor mount. Tighten the mounting bolts on the oil pan, then the mounting bolts on the engine block, 36 ft. lbs. (49 Nm). Install the A/C compressor onto the mount and tighten the bolts to 16 ft. lbs. (22 Nm).
- Install the speed sensor and tighten the mounting bolt to 7 ft. lbs. (10 Nm).
- Install new set rings on the CV-joints and press them into their sockets.
- Refill the differential.
- Connect the lower ball joints to the control arms and install the nuts, tighten them to 36-43 ft. lbs. (49-59 Nm) and install a new cotter pin. Tighten the strut fork bolts to 47 ft. lbs. (64 Nm). Install the front wheels.
- Carefully lower the vehicle.
- Remove the chain hoist.
- Refill the engine oil and cooling system.
- Install the air cleaner and intake duct.
- Bleed the cooling system by opening the bleeder on the upper radiator hose inlet when filling the system.
- Connect the negative battery cable.
- Raise and safely support the vehicle.
- Drain the engine oil into a suitable container.
- Remove the exhaust pipe if necessary.
- Unfasten the oil pan mounting bolts, then remove the oil pan.
- Clean the sealing surface on the engine and oil pan flange.
See Figure 11
- Apply a bead of sealant to the oil pan flange and install the oil pan. Tighten the bolts, in the sequence shown, to 104 inch lbs. (12 Nm).
- If removed, install the exhaust pipe.
- Add the correct amount of engine oil to the crankcase.
- Start the engine and check for leaks.
3.2L and 3.5L Engines
- Disconnect the negative, then the positive battery cables.
- Remove the air conditioning compressor drive belt.
- Raise and safely support the vehicle.
- Remove the front wheels and splash shield.
- Remove the strut forks. Remove the lower ball joint nut and use a ball joint press tool to disconnect the ball joint from the control arm.
- Remove the halfshafts from the differential and the intermediate shaft.
- Remove the intermediate shaft from the oil pan.
- Drain the oil from the differential into a sealable container the install the drain plug with a new washer.
- Drain the engine oil into a sealable container.
- If equipped, disconnect the Vehicle Speed Sensor (VSS) harness, then remove the VSS/power steering speed sensor. Do not disconnect the fluid hoses, support the sensor out of the way.
- Remove the right front beam bridge.
- Remove the lower plate from the rack and pinion, install the two rack and pinion mounting bolts that were removed.
- Remove the 36mm sealing bolt on the transaxle. Ensure that the transaxle is in 1st gear (manual) or P (automatic).
- Disconnect the extension shaft from the differential with the extension shaft puller part number 07LAC-PW50101 or its equivalent.
- Remove the differential mounting bolts and the 26mm shim, then remove the differential.
- Detach the A/C compressor clutch connector, then remove the compressor. Do not disconnect the A/C hoses from the compressor and do not let the compressor hang by the hoses.
- Remove the rear engine stiffener.
- Remove the flywheel cover or the torque converter covers.
- Remove the oil pan. Do not lose the dowel pins from the oil pan.
- Clean the oil pan and cylinder block mating surfaces, then apply liquid gasket to the cylinder block. Be sure that the mating surfaces are clean and dry before installing the liquid gasket. Do not apply liquid gasket to the O-ring grooves.
See Figure 12
- Install the dowel pins to the oil pan and new O-rings coated with clean oil. Install the oil pan to the cylinder block. Coat the oil pan bolts with liquid gasket, then install them. Tighten the bolts, in the proper sequence, to 16 ft. lbs. (22 Nm).
- For manual transaxle, install the flywheel cover and engine stiffener.
- For automatic transaxle, install the torque converter covers and tighten the mounting bolts to 104 inch lbs. (12 Nm).
- Install the rear engine stiffener. Tighten the bolt attaching the engine stiffener to the transaxle first, to 47 ft. lbs. (64 Nm), then tighten the bolts to the engine block to 16 ft. lbs. (22 Nm).
- Install the A/C compressor to the engine block and tighten the mounting bolts to 16 ft. lbs. (22 Nm).
- Attach the A/C clutch connector.
- Install the dowel pins to the differential, then install the differential to the engine. Install the mounti