Honda Prelude Accord Civic S2000 2001-2006

Engine

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Removal & Installation




NOTE
The original radio contains a coded anti-theft circuit. Obtain the security code number before disconnecting the battery cables.


NOTE
The original radio contains a coded anti-theft circuit. Obtain the security code number before disconnecting the battery cables.

Accord
2001-02 Models
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Obtain the anti-theft code for the radio, then disconnect the battery cables. Be sure to disconnect the negative cable first.
  4.  
  5. Remove the air intake duct.
  6.  
  7. Secure the hood in the open position with a long prop rod such as P/N 74145-S84-A00.
  8.  
  9. Remove or disconnect the following:

    Both battery cables and the connector from the underhood relay box
     
    Battery and tray, on the 3.0L engine
     
    Bolt securing the relay box to the body
     
    Accelerator and cruise control cables from the throttle body and bracket
     

  10.  
  11. Properly relieve the fuel system pressure.

    Fuel hoses from the fuel rail
     
    Brake booster vacuum and evaporative emissions (EVAP) canister hoses
     
    Vacuum hose from the canister
     
    Hose securing the power steering hose on the engine
     
    Power steering pump belt, then remove the pump and position it out of the way. Use wire if necessary.
     
    Powertrain Control Module (PCM) connectors from the control module. Remove the grommet and pull the connectors through.
     
    Wiring harness connectors at the right side of the engine compartment for 2.3L engine and on the left side for the 3.0L engine.
     

  12.  
  13. On the 2.3L engine, remove the starter cable (A) and clamp (B). Remove the ground cable (C) and back-up light switch connectors (D). On the 3.0L engine, remove the starter wiring from the engine compartment attaching points.

    Click image to see an enlarged view

    Fig. Starter cable, clamp, ground cable and back-up light switch connector locations- 2.3L engine

  14.  
  15. On vehicles with a manual transaxle, disconnect the shift and select cables from the transaxle. Remove the slave cylinder mounting bolts and position the cylinder out of the way. Be sure not to bend the line.
  16.  
  17. Remove or disconnect the following:

    Rear engine mount through-bolt and stiffener
     
    Front engine mount bracket mounting bolts and loosen the through-bolt
     
    Radiator cap
     

  18.  
  19. Raise and safely support the vehicle.
  20.  
  21. Remove or disconnect the following:

    Front tires
     
    Engine under cover
     

  22.  
  23. Loosen the radiator drain plug and drain the coolant.
  24.  
  25. Drain the transaxle oil or fluid, and then reinstall the plug using a new washer.
  26.  
  27. Drain the engine oil, and then reinstall the plug using a new washer.
  28.  
  29. Lower the vehicle and remove the upper and lower radiator hoses and heater hoses from the engine.
  30.  
  31. On vehicles with an automatic transaxle, disconnect the ATF fluid cooler lines.
  32.  
  33. Remove the air conditioning compressor from the engine and position it to the side without disconnecting the hoses.
  34.  
  35. Raise the vehicle and remove the front exhaust pipe.
  36.  
  37. On vehicles with automatic transaxle, remove the 2 bolts (A) for the shift cable holder (B), then remove the shift cable cover (C). To prevent damage to the linkage, be sure to remove the shift cable holder before removing the bolts for the cover.

    Click image to see an enlarged view

    Fig. Automatic transaxle linkage components-2.3L engine

  38.  
  39. Remove or disconnect the following:

    Lockbolt (D) from the control lever (E), then the shift cable (F) with the control lever
     
    Through-bolt securing the bottom of the shock absorber to the control arm
     
    Halfshafts
     
    Rear engine mounting bracket
     
    2 flange bolts from each of the radius rods
     

  40.  
  41. Mark the location of the front beams (A) on the rear beams (B). Remove the 4 bolts and the subframe.

    Click image to see an enlarged view

    Fig. Be sure to mark the location of the front beams (A) on the rear beams (B) before removing the subframe-2.3L engine



    Click image to see an enlarged view

    Fig. Mark the location of the front beams (A) on the rear beams (B) before removing the subframe-3.0L engine



    Click image to see an enlarged view

    Fig. Engine lifting points-2.3L engine shown, 2.4L engine similar



    Click image to see an enlarged view

    Fig. Engine lifting points-3.0L engine

  42.  
  43. Lower the vehicle about half way and attach a chain hoist to the engine lifting points as shown. Apply slight upward pressure to the engine/transaxle assembly.
  44.  
  45. Remove the remaining engine and transaxle mounting brackets.
  46.  
  47. Lower the engine about 6 in. (150mm) and check that the engine/transaxle is free of any hoses, cables or wiring.
  48.  
  49. Lower the assembly completely and remove it from under the vehicle.
  50.  

To install:

  1. Lift the engine into position and install the engine mounting brackets. Tighten the retainers as follows:
    1. On the 2.3L engine, tighten the engine mounting bolts and nuts to 40 ft. lbs. (54 Nm).
    2.  
    3. On the 3.0L, tighten the bolts to 28 ft. lbs. (38 Nm).
    4.  

  2.  
  3. On the 3.0L engine, install the air conditioning compressor. Tighten the bolts to 16 ft. lbs. (22 Nm).
  4.  
  5. Install the transaxle mounting bracket, and tighten the retainers as follows:
    1. On the 2.3L engine, tighten the nuts to 28 ft. lbs. (38 Nm) and the through-bolt to 40 ft. lbs. (54 Nm).
    2.  
    3. On the 3.0L engine, tighten the bolts to 28 ft. lbs. (38 Nm).
    4.  

  6.  
  7. Install the sub-frame in its original position, and tighten the retainers as follows:
    1. On the 2.3L engine, tighten the rear bolts to 47 ft. lbs. (64 Nm) and the front bolts to 76 ft. lbs. (103 Nm).
    2.  
    3. On the 3.0L engine, tighten the rear bolts to 40 ft. lbs. (54 Nm), front bolts to 76 ft. lbs. (103 Nm) and the nuts to 28 ft. lbs. (38 Nm).
    4.  

  8.  
  9. On the 2.3L engine, install or connect the following:

    Radius rod bolts: 119 ft. lbs. (162 Nm)
     
    Rear mount bracket: 40 ft. lbs. (54 Nm)
     
    Stiffener. Tighten the through-bolt to 47 ft. lbs. (64 Nm) for manual transaxles or the nut and bolt to 28 ft. lbs. (38 Nm) for automatic transaxles.
     
    3 front mounting bracket bolts: 28 ft. lbs. (38 Nm). Then, tighten the through-bolt to 47 ft. lbs. (64 Nm).
     
    Air conditioning compressor: 16 ft. lbs. (22 Nm)
     

  10.  
  11. On the 3.0L engine, install or connect the following:

    Radius rod bolts: 119 ft. lbs. (162 Nm)
     
    Front mounting bracket support nut: 40 ft. lbs. (54 Nm)
     
    Rear mounting bracket nut and bolt. Tighten the nut to 40 ft. lbs. (54 Nm) and the bolt to 28 ft. lbs. (38 Nm).
     
    Side mounting bracket. Tighten the bolts to 40 ft. lbs. (54 Nm) and the through-bolt to 40 ft. lbs. (54 Nm).
     
    Exhaust system
     
    Shift linkage, if equipped with an automatic transaxle
     

  12.  
  13. The remainder of the installation is the reverse of the removal.
  14.  
  15. Refill and bleed the cooling system.
    WARNING
    Operating the engine without the proper amount and type of engine oil will result in severe engine damage.

  16.  
  17. Fill the engine with the correct amount of oil.
  18.  
  19. Install the battery if removed. Start the engine and check for leaks.
  20.  

2003-06 2.4L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Note the radio security code and the radio presets.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Disconnect the negative battery cable, than the positive cable. Remove the hood support from the driver-s side of the vehicle. Lock the hood in the full up position.
  8.  
  9. Remove the battery.
  10.  
  11. Disconnect the air intake sensor. Remove the vacuum hose, and breather pipe then remove the intake air duct.
  12.  
  13. Remove the air cleaner housing. Remove the harness clamp.
  14.  
  15. Remove the harness terminal wires. Remove the bolts retaining the battery base and remove it. Remove the battery cables from the under hood fuse/relay box. Disconnect the harness connector. Remove the two retaining bolts holding the under hood fuse/relay box in place. Remove the box.
  16.  
  17. On 2003-2005 vehicles, remove the throttle cable and cruise control actuator cable.
  18.  
  19. On 2006 vehicles, remove the harness clamp and the strut brace.
  20.  
  21. Remove the quick connect fitting cover. Disconnect the fuel feed hose. Remove the evaporative emission canister hose and brake booster vacuum hose.
  22.  
  23. On 2003-2005 vehicles, remove the harness clamp then disconnect the engine wiring harness connectors on the left side of the engine compartment.
  24.  
  25. On 2006 vehicles, disconnect the ECM/PCM connectors and the main wire harness connectors. Disconnect the accelerator pedal position (APP) sensor connector. Remove the harness clamps and grommet. Pull the wire harness thru the bulkhead.
  26.  
  27. If equipped with manual transaxle, remove the clutch slave cylinder and clutch line bracket mounting bolts. Remove the shift and select cables.
  28.  
  29. Disconnect the air fuel sensor connector. Remove the drive belt.
  30.  
  31. Remove the power steering pump. Remove the air conditioning compressor without disconnecting the air conditioning hoses. Position the compressor to the side.
  32.  
  33. Remove the radiator cap. Raise and support the vehicle safely. Remove the front tires. Drain the radiator. Drain the transaxle. Drain the engine oil.
  34.  
  35. Disconnect the stabilizer links. Remove the damper fork. Separate the knuckles from the lower arm ball joints. Remove the driveshafts. Remove the exhaust pipe.
  36.  
  37. On automatic transaxle remove the bolts securing the shift cable holder. Remove the shift cable cover. Remove the spring clip and control pin then separate the shift cable from the control lever.
  38.  
  39. Remove the transaxle lower front and lower rear mounts. Lower the vehicle. On automatic transaxle models, remove the fluid cooler lines.
  40.  
  41. Remove the upper radiator hose and heater hoses. Remove the lower radiator hoses. Remove the battery ground cable and upper bracket.
  42.  
  43. Properly attach the engine lifting device.
  44.  
  45. If equipped with manual transaxle, remove the ground cable. Remove the transaxle upper mount/bracket assembly and the clutch line clamp bracket. Remove the front stop then the front mount bolt.
  46.  
  47. If equipped with automatic transaxle, remove the ground cable. Remove the transaxle upper mount/bracket assembly. Remove the vacuum hose. Remove the front mount stop and vacuum hose clamp bracket. Remove the front transaxle mount bolt.
  48.  
  49. Remove the rear mount stop retaining nuts. Remove the rear mount stop. Remove the rear mount bolt.
  50.  
  51. Be sure that the engine/transaxle assembly is free from all hoses, vacuum lines and electrical wires and connectors.
  52.  
  53. Remove the engine/transaxle assembly from under the vehicle.
  54.  

To install:

  1. Installation is the reverse of the removal procedure. Be sure to check and adjust all required fluid levels.
  2.  
  3. Reprogram the ECM/PCM with the HDS, turn the ignition switch the OFF position. Turn the ignition switch to the ON position. Wait thirty seconds. Turn the ignition switch OFF and disconnect the HDS from the DLC.
  4.  
  5. Reprogram the ECM engine idle characteristics. Be sure all electrical items are OFF.
  6.  
  7. Start the engine. Hold the idle speed at 3000 RPM-s in neutral until the radiator fan comes on or the temperature reached 176 degrees.
  8.  
  9. Let the engine idle for about five minutes with the throttle fully closed.
  10.  
  11. If the radiator fan comes on during the five minutes, do not count this toward the five minute programming time.
  12.  
  13. Enter the antitheft codes for the radio and the navigation system. Set the clock.
  14.  
  15. Reprogram the power window control unit as follows.
  16.  
  17. Turn the ignition switch ON. Lower the window, all the way down. Open the driver-s side door.
  18.  
  19. Turn the ignition switch OFF. Push and hold the drivers window DOWN switch. Turn the ignition switch ON. Release the driver-s window DOWN switch. This must be done within five seconds.
  20.  
  21. Repeat the above step three more times. Wait one second.
  22.  
  23. Confirm that the AUTO UP and AUTO DOWN do not work. If they work repeat the procedure, paying close attention to the five second time limit
  24.  
  25. Move the driver-s window all the way down by holding the drivers window DOWN switch to the AUTO DOWN position.
  26.  
  27. Pull up and hold the driver-s window UP switch to the AUTO UP position until the window reaches the fully closed position. Hold the switch for one second.
  28.  
  29. Confirm that the power window master switch has been reset by using the driver-s window AUTO UP and DOWN function.
  30.  
  31. If the AUTO UP and DOWN feature is still not working, repeat the complete procedure, paying close attention to the five second time limit.
  32.  

2003-06 3.0L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Note the radio security code and the radio presets.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Disconnect the negative battery cable, than the positive cable. Remove the battery.
  8.  
  9. Remove the windshield wiper arms. Remove the cowl cover. Remove the bulkhead cover.
  10.  
  11. Remove the support struts from the engine hood. Move the hood to a vertical position. Install the right side hood support.
  12.  
  13. Drain the power steering fluid. Plug the reservoir and return hose. Remove the air cleaner housing.
  14.  
  15. Remove the harness terminal wires. Remove the bolts retaining the battery base and remove it. Remove the battery cables from the under hood fuse/relay box. Disconnect the harness connector. Remove the two retaining bolts holding the under hood fuse/relay box in place. Remove the box. Remove the ground cable.
  16.  
  17. Remove the brake booster vacuum hose, evaporative emission canister hose and vacuum hose. Remove the harness clamp and disconnect the engine wiring harness from the left side of the engine compartment.
  18.  
  19. Remove the drive belt. Remove the power steering pump outlet line from the power steering pump. Remove the power steering hose from the clamp. Remove the power steering system fluid reservoir from the clamp.
  20.  
  21. Remove the steering gear protective cover. Lock the steering wheel in position. Make a reference mark across the steering joint and steering gear box pinion shaft. Remove the steering joint bolt. Disconnect the steering joint from the steering gearbox pinion shaft.
    NOTE
    To prevent damage to the cable reel, do not turn the steering wheel once the steering joint has been removed.

  22.  
  23. Disconnect the fan motor connector. Disconnect the compressor clutch connector. Remove the coolant tank.
  24.  
  25. Remove the condenser fan shroud retaining bolts. Remove the fan shroud. Remove the four bolts retaining the air conditioning compressor.
  26.  
  27. If equipped with manual transaxle, remove the ground cable from the shift cable holder. Remove the bolts retaining the shift cable holder. Remove the shift cable and the select cable. Remove the clutch slave cylinder mounting bolt. Remove the slave cylinder.
    NOTE
    Do not operate the clutch pedal once the slave cylinder has been removed.

  28.  
  29. Remove the radiator cap. Raise and safely support the vehicle. Remove the front tires. Remove the splash pan.
  30.  
  31. Drain the radiator. Drain the engine oil. Drain the transaxle.
  32.  
  33. Disconnect the stabilizer links. Remove the damper fork. Separate the tie rod end ball joints from the knuckles. Separate the knuckles from the lower arms.
  34.  
  35. Remove the driveshafts. Remove the exhaust pipe.
  36.  
  37. On automatic transaxle, Remove the shift cable cover retaining bolt. Remove the cover. Remove the lock bolt retaining then control lever, remove the lever assembly.
    NOTE
    To prevent damage to the control lever joint, be sure to remove the bolts retaining the shift cable holder before removing the bolts retaining the shift cable cover.

  38.  
  39. Remove and plug the power steering line hose. Disconnect the power steering pressure switch connector.
  40.  
  41. Remove the nuts retaining the transaxle lower front mount and lower rear mount. Lower the vehicle to the ground.
  42.  
  43. Remove the radiator hoses. Remove the heater hoses. Remove the connector clamp from the front and rear cylinder head.
    NOTE
    Removal of these bolts is necessary if using engine support tool AAR-T-12566 and VSB02C000919.

  44.  
  45. Lift and support the engine, using the engine support tool.
  46.  
  47. If equipped with manual transaxle, remove the ground cable. If equipped with automatic transaxle, remove the transaxle upper mount bracket and vacuum hose.
  48.  
  49. Remove the front mount stop. Remove the front mount bolt. Remove the rear mount stop. Remove the rear mount bolt.
  50.  
  51. If equipped with manual transaxle, remove the two bolts retaining the shift cable bracket. Raise and safely support the vehicle.
  52.  
  53. Matchmark the subframe with the edge of the subframe stiffener. Attach special tool VSB02C000016 by hanging the belt over the front of the subframe. Secure the belt to the stop.
  54.  
  55. Raise the jack, line up the slots in the tool arms with the bolt holes on the corner of the jack base. Attach the four bolts.
  56.  
  57. Remove the subframe mid mount. Remove the subframe. Lower the vehicle to the ground.
  58.  
  59. Attach a lifting device. Raise the engine/transaxle assembly up slightly. Remove the engine support tool.
  60.  
  61. Remove the two bolts retaining the side engine mount bracket.
  62.  
  63. Be sure that the engine/transaxle assembly is free from all hoses, vacuum lines and electrical wires and connectors.
  64.  
  65. Remove the engine/transaxle assembly from under the vehicle.
  66.  

To install:

  1. Installation is the reverse of the removal procedure. Be sure to check and adjust all required fluid levels.
  2.  
  3. Reprogram the ECM/PCM with the HDS, turn the ignition switch the OFF position. Turn the ignition switch to the ON position. Wait thirty seconds. Turn the ignition switch OFF and disconnect the HDS from the DLC.
  4.  
  5. Reprogram the crankshaft position (CKP) pattern. Run the engine until the operating temperature reaches 176 degree. With the engine stopped clear the CKP pattern. Turn the ignition switch OFF. Turn the ignition switch ON and wait thirty seconds.
  6.  
  7. Road test the vehicle on a level surface. Decelerate the engine speed of 2500 rpm to 1000 rpm. If equipped with automatic transaxle use two Drive positions. If equipped with manual transaxle use first gear.
  8.  
  9. Stop the vehicle, but keep the engine running.
  10.  
  11. Check PULSAR F/B LEARN in the data list with the HDS. If not complete repeat the procedure. If complete, road test the vehicle on a level surface. Decelerate the engine speed of 5000 rpm to 3000 rpm. If equipped with automatic transaxle use two Drive positions. If equipped with manual transaxle use first gear.
  12.  
  13. Stop the vehicle, but keep the engine running.
  14.  
  15. Check PULSAR F/B LEARN in the data list with the HDS. If not complete repeat the procedure.
  16.  
  17. If completed, turn the ignition switch OFF. Turn the ignition switch ON, wait thirty seconds. The learning procedure is now complete.
  18.  
  19. Enter the antitheft codes for the radio and the navigation system. Set the clock.
  20.  
  21. Reprogram the power window control unit as follows.
  22.  
  23. Turn the ignition switch ON. Lower the window, all the way down. Open the driver-s side door.
  24.  
  25. Turn the ignition switch OFF. Push and hold the drivers window DOWN switch. Turn the ignition switch ON. Release the driver-s window DOWN switch. This must be done within five seconds.
  26.  
  27. Repeat the above step three more times. Wait one second.
  28.  
  29. Confirm that the AUTO UP and AUTO DOWN do not work. If they work repeat the procedure, paying close attention to the five second time limit
  30.  
  31. Move the driver-s window all the way down by holding the drivers window DOWN switch to the AUTO DOWN position.
  32.  
  33. Pull up and hold the driver-s window UP switch to the AUTO UP position until the window reaches the fully closed position. Hold the switch for one second.
  34.  
  35. Confirm that the power window master switch has been reset by using the driver-s window AUTO UP and DOWN function.
  36.  
  37. If the AUTO UP and DOWN feature is still not working, repeat the complete procedure, paying close attention to the five second time limit.
  38.  

Civic
2001-05 Models
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Disconnect the negative and positive battery cables. Wait at least 3 minutes before working around the air bags.
    NOTE
    The engine and transaxle are removed from the vehicle as 1 unit.

  4.  
  5. Support the hood as far open as possible. If the hood is to be removed, first matchmark the hinge plates with a felt-tipped marker.
  6.  
  7. Remove the battery from the vehicle. Unbolt and remove the battery tray.
  8.  
  9. Disconnect the battery and alternator cables from the underhood fuse and relay box on the right shock tower.
  10.  
  11. Remove the lower right kick panel to expose the Powertrain Control Module (PCM).
  12.  
  13. Label and disconnect the 5 wiring harness connections from the PCM.
  14.  
  15. Unbolt the main wiring harness retainer from the rear of the fuse and relay box on the right side of the bulkhead. Carefully pull the grommet out of its bulkhead opening. Next, pull the PCM harness and connectors through the opening. Be careful not to damage the wiring, insulation, or connectors.
  16.  
  17. Relieve the fuel pressure:
    1. Loosen the fuel filler cap.
    2.  
    3. Use a box-end wrench and a flare nut wrench to hold the fuel filter banjo fitting.
    4.  
    5. Place a shop towel over the fuel filter to catch the fuel spray.
    6.  
    7. Slowly loosen the fuel filter service bolt 1 full turn.
    8.  
    9. Clean up any spilled fuel.
    10.  

  18.  
  19. Remove or disconnect the following:

    Intake air duct and air cleaner
     
    Intake Air Temperature (IAT) sensor connector from the air cleaner case, if equipped
     
    Fuel feed hose from the fuel filter
     
    Fuel return hose from the fuel rail
     
    Intake manifold/throttle body vacuum hoses
     
    Brake booster vacuum hose
     
    Evaporative emissions (EVAP) canister vacuum hose
     
    Power Steering Pressure (PSP) switch and detach its clamp from the bracket below the brake booster
     
    Transaxle ground cable
     
    Radiator hose bracket
     

  20.  
  21. Loosen the throttle cable locknut, then disconnect the cable from the throttle body linkage. Move the cable aside without kinking it.
  22.  
  23. Loosen the power steering pump mounting bolts. Slip power steering belt off its pulleys. Unbolt the steering pump and move it out of the work area. Don't disconnect the hydraulic hoses.
    NOTE
    Label the connectors before detaching them.

  24.  
  25. Remove or disconnect the following:

    Engine wiring harness connectors at the left side of the engine compartment
     

  26.  
  27. Drain the coolant from the radiator and engine block.
  28.  
  29. Remove or disconnect the following:

    Upper and lower radiator hoses
     
    Heater hoses from the cylinder head
     

  30.  
  31. If equipped with a CVT transaxle, loosen the shift cable locknut. Remove the spring clip and washers and disconnect the shift cable from its linkage. Be careful not to kink the cable or damage its boot.
  32.  
  33. Remove or disconnect the following:

    Hydraulic line brackets from the top of the transaxle case, if equipped with a manual transaxle
     

  34.  
  35. Attach a chain hoist to the engine lifting brackets. Don't raise the hoist to lift the engine yet.
  36.  
  37. Raise the vehicle and support it safely. Remove the front wheels.
  38.  
  39. Remove or disconnect the following:

    Engine splash shield
     

  40.  
  41. Drain the engine oil.
  42.  
  43. Drain the fluid from the transaxle.
  44.  
  45. Remove or disconnect the following:

    Left front engine mount bracket from the shock tower, if equipped with air conditioning
     

  46.  
  47. Loosen the compressor idler pulley and adjusting bolt. Slip the belt around the engine mount stud to remove it.
  48.  
  49. Remove or disconnect the following:

    Compressor mounting bolts to separate the compressor from its mounting plate. Move the compressor out of the work area. Do not disconnect the air conditioning refrigerant lines.
     

  50.  
  51. Remove or disconnect the following:

    ATF cooler lines, if equipped. Plug the cooler lines to prevent fluid leakage and contamination
     
    Slave cylinder from the transaxle case without disconnecting its hydraulic line, if equipped with manual transaxle
     
    Front exhaust pipe from the exhaust manifold and catalytic converter. Unbolt its hanger bracket and remove the exhaust pipe.
     
    Shift cable from the transaxle control shaft, if equipped with automatic transaxle
     
    Shift rod and extension rod from the transaxle, if equipped with manual transaxle
     
    Strut damper fork
     
    Steering knuckle ball joint from the lower control arm using a ball joint separator
     

  52.  
  53. Pry the inboard CV-joints from the transaxle. Then, move the halfshafts away from the transaxle and wire them to the undercarriage of the vehicle. Tie plastic bags over the inboard CV-joints to prevent damage to the boots and splined shafts.
  54.  
  55. Raise the hoist slightly to take up the weight of the engine and transaxle assembly.
  56.  
  57. Disconnect the engine mounts in the following order:
    1. Unbolt and remove the left front engine mount.
    2.  
    3. Unbolt and remove the right front engine mount and bracket assembly.
    4.  
    5. Remove the rear engine mount through-bolt. Then, unbolt the rear mount bracket from the engine block.
    6.  

  58.  
  59. If necessary, lower the vehicle slightly to gain access to the side engine and transaxle mounts. Do not release the tension on the chain hoist. The engine must be securely supported.
  60.  
  61. Unbolt the side engine mount bracket from the engine block bracket and mount damper.
  62.  
  63. Unbolt the transaxle mount bracket from the transaxle case. Then, unbolt the mount from the shock tower.
  64.  
  65. Raise the chain hoist to lift the engine a few inches off of its mounts.
  66.  
  67. Verify that all electrical, vacuum, and fuel lines have been disconnected.
  68.  
  69. Raise the engine and transaxle assembly and remove it from the vehicle.
  70.  

To install:


NOTE
Use new self-locking nuts and gaskets when installing the front exhaust pipe and when assembling the front suspension. Use new set rings on the inboard CV-joint splined shafts.

  1. Lower the engine and transaxle assembly into the vehicle.
  2.  
  3. Install and connect the engine and transaxle mounts and brackets. Use new self-locking nuts and color-coded bolts. At this point, only tighten the mounting nuts and bolts by hand.
  4.  
  5. Before installing the left front engine mount, fit the air conditioning compressor back into place and install the compressor belt. Tighten the compressor bolts to 17 ft. lbs. (24 Nm).
    NOTE
    Failure to tighten the bolts in the proper sequence can cause excessive noise and vibration and reduce bushing life. Be sure to check that the bushings are not twisted or offset.

  6.  
  7. The engine and transaxle mount and bracket fasteners must be tightened in the proper sequence with the weight of the engine resting upon them. This step is important for engine mount pre-loading. Tighten the engine mount bolts in the following sequence:
    1. Transaxle mount bolts: 47 ft. lbs. (64 Nm); or 28 ft. lbs. (38 Nm) for CVT-equipped vehicles.
    2.  
    3. Side engine mount bracket nuts: 54 ft. lbs. (74 Nm).
    4.  
    5. Rear mount bracket bolts: 61 ft. lbs. (83 Nm); or 43 ft. lbs. (59 Nm) for CVT-equipped vehicles.
    6.  
    7. Rear mount through-bolt: 43 ft. lbs. (59 Nm).
    8.  
    9. Transaxle mount bracket nuts or bolts: 47 ft. lbs. (64 Nm).
    10.  
    11. Transaxle mount through-bolt: 54 ft. lbs. (74 Nm).
    12.  
    13. Right front mount bracket bolts: 33 ft. lbs. (44 Nm).
    14.  
    15. Right front mount carrier bolts: 33 ft. lbs. (44 Nm).
    16.  
    17. Left front mount: stud: 61 ft. lbs. (85 Nm); carrier bolts: 33 ft. lbs. (44 Nm); nut: 43 ft. lbs. (59 Nm).
    18.  

  8.  
  9. Remove the chain hoist from the engine lifting hooks.
  10.  
  11. Install or connect the following:

    New set rings on the inboard splined shafts of each halfshaft. Check that the set ring on each inboard CV-joint clicks into place when the halfshafts are installed into the transaxle.
     
    Damper fork and reconnect the lower ball joint. When the weight of the vehicle is resting on its suspension, tighten the pinch bolt to 32 ft. lbs. (44 Nm) and the fork bolt to 47 ft. lbs. (65 Nm). Tighten the ball joint castle nut to 36-43 ft. lbs. (50-60 Nm). Next, tighten the castle nut only enough to install a new cotter pin.
     
    Slave cylinder, if equipped. Tighten the slave cylinder mounting bolts to 16 ft. lbs. (22 Nm). If the clutch hydraulic line was disconnected, air must be bled from the system.
     
    Transaxle shift and extension rods to the linkage at the transaxle case, if equipped. Install a new 8mm spring pin into the shift rod linkage. Then, install the retainer clip and boot. Tighten the extension rod bolt to 16 ft. lbs. (22 Nm).
     
    Shift cable to the control shaft, if equipped with an automatic transaxle. Use a new lockwasher and tighten the lockbolt to 10 ft. lbs. (14 Nm). Tighten the shift cable cover bolts to 16 ft. lbs. (22 Nm). Install the shift cable cover and tighten its bolts to 16 ft. lbs. (22 Nm).
     

  12.  
  13. Install the front exhaust pipe using new self-locking nuts:
    1. Tighten the exhaust manifold nuts to 40 ft. lbs. (55 Nm).
    2.  

  14.  
  15. Install or connect the following:

    Tighten the exhaust flange bolts to 16 ft. lbs. (22 Nm).
     
    ATF cooler lines. If the rubber cooler lines are cracked or stressed, they must be replaced.
     
    Engine splash shield
     

  16.  
  17. Refill the engine with fresh oil.
  18.  
  19. Refill the transaxle with the proper fluid.
  20.  
  21. Lower the vehicle.
  22.  
  23. If equipped, fit the clutch hydraulic line brackets back into place. Tighten the 8mm bolts to 17 ft. lbs. (24 Nm). Tighten the 6mm bolts to 96 inch lbs. (11 Nm).
  24.  
  25. If equipped with a CVT transaxle, reconnect the shift cable to the linkage. Use new plastic washers and a new spring clip. Tighten the locknut to 22 ft. lbs. (29 Nm).
  26.  
  27. Adjust the alternator and air conditioning compressor belt tensions.
  28.  
  29. Install or connect the following:

    Upper and lower radiator hoses and the heater hoses
     
    Power steering pump into its mounts. Adjust the pump belt tension, then tighten the mounting bolts to 17 ft. lbs. (24 Nm).
     
    PSP switch connector and attach its harness clamp
     
    Intake manifold/throttle body vacuum hoses
     
    Brake booster vacuum hose
     
    EVAP canister vacuum hose
     
    Fuel line fittings to the fuel filter and fuel rail. Use new sealing washers. Tighten the banjo fittings to 25 ft. lbs. (33 Nm), and the service bolts to 11 ft. lbs. (15 Nm). Don't over tighten the fittings
     
    Throttle cable and adjust its deflection to 10-12mm (0.39-0.47 in.).
     

  30.  
  31. Feed the PCM harness through the hole in the bulkhead. Apply sealant to the grommet, then install the retainer.
  32.  
  33. Install or connect the following:

    Engine wiring harness and ground cables that were disconnected during removal. Be sure the grounds are free of corrosion to ensure good contact.
     
    Fuse and relay box back into position
     
    Battery and alternator cables
     
    Air cleaner case and air intake duct
     
    IAT connector
     
    5 PCM connectors and kick panel
     
    Battery tray and the battery
     

  34.  
  35. Verify that all wiring harnesses and grounds, vacuum lines, fuel lines have been reconnected.
  36.  
  37. Refill the radiator with fresh coolant.
  38.  
  39. If it was removed, install the hood. Reconnect the windshield washer tubing. After installation, check to be sure that the hood, fender, and grille panel gaps are equal.
  40.  
  41. Reconnect the positive and negative battery cables.
  42.  
  43. Turn the ignition switch to the ON position, but don't start the engine. Then, turn the ignition OFF . Repeat this procedure 2 or 3 times and check for fuel leaks.
  44.  
  45. Start the engine and allow it to warm up to its normal operating temperature.
  46.  
  47. Reprogram the ECM engine idle characteristics. Be sure all electrical items are OFF.
  48.  
  49. Start the engine. Hold the idle speed at 3000 RPM-s in neutral until the radiator fan comes on or the temperature reached 194 degrees.
  50.  
  51. Let the engine idle for about five minutes with the throttle fully closed.
  52.  
  53. If the radiator fan comes on during the five minutes, do not count this toward the five minute programming time.
  54.  
  55. Bleed the air from the cooling system with the heater valve open.
  56.  
  57. Check the throttle cable deflection and operation.
  58.  
  59. Check and adjust the ignition timing.
  60.  
  61. Shut the engine off and check the drive belt adjustments.
  62.  
  63. Check all fluid levels and top up as necessary.
  64.  
  65. Check and adjust the front wheel alignment.
  66.  
  67. Road test the vehicle.
  68.  

2006 Models 1.8L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Note the radio security code and the radio presets.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Disconnect the negative battery cable, than the positive cable. Remove the hood support from the driver-s side of the vehicle. Lock the hood in the full up position.
  8.  
  9. Remove the battery. Remove the air cleaner assembly. Remove the cowl cover and undercover panel.
  10.  
  11. Remove the fuel line quick connect fitting cover. Disconnect the fuel feed hose. Remove the evaporative emission canister hose, power brake vacuum booster hoses and power steering hose clamp.
  12.  
  13. Remove the battery cables from the under hood fuse/relay box. Remove the harness clamps. Remove the ECM /PCM control module cover. Remove the assembly retaining bolts. Disconnect the electrical connectors. Disconnect the engine wiring harness connector. Remove the harness clamps.
  14.  
  15. If equipped with manual transaxle, remove the bolts retaining the harness holder. Remove the harness clamp. Remove the shift cable. Remove the clutch slave cylinder and line bracket mounting bolt.
  16.  
  17. Remove the drive belt. Remove the harness cover. Disconnect the ignition coil connectors. Remove the four retaining bolts holding the harness holders in place. Remove the front harness holder.
  18.  
  19. Remove the breather pipe, air cleaner bracket and air harness bracket. Remove the harness holder bracket.
  20.  
  21. Attach the engine support tool (AAR-T-12566) to the vehicle. Remove the radiator cap.
  22.  
  23. Raise and support the vehicle safely. Remove the front tires. Remove the splash shield. Drain the radiator. Drain the engine oil. Drain the transaxle fluid.
  24.  
  25. Remove the exhaust pipe. If equipped with automatic transaxle, remove the shift cable.
  26.  
  27. Separate the stabilizer links. Separate the knuckles from the lower arms. Remove the driveshafts.
  28.  
  29. Remove the power steering pump retaining bolts and position it to the side. It is not necessary to disconnect the hoses from the pump.
  30.  
  31. Unclamp the power steering line clamp from the subframe. Remove the power steering line mounting bolts.
  32.  
  33. Remove the gearbox mounting bolt. Remove the steering gearbox stiffener
  34.  
  35. Lower the vehicle to the ground. Remove the radiator.
  36.  
  37. Disconnect the air conditioning compressor clutch connector and remove the harness clamp. Remove the compressor assembly, without disconnecting the refrigerant lines.
  38.  
  39. Remove the heater hoses. Raise and support the vehicle safely. Remove the lower torque rod.
  40.  
  41. Matchmark the subframe with the edge of the subframe stiffener. Attach special tool VSB02C000016 by hanging the belt over the front of the subframe. Secure the belt to the stop.
  42.  
  43. Raise the jack, line up the slots in the tool arms with the bolt holes on the corner of the jack base. Attach the four bolts.
  44.  
  45. Remove the subframe mid mount. Remove the subframe. Lower the vehicle to the ground. Remove the ground cable.
  46.  
  47. Attach a lifting device. Raise the engine/transaxle assembly up slightly. Remove the engine support tool.
  48.  
  49. Remove the side engine mount bracket. Remove the transaxle mounting bolt and nuts. Remove the ground cable.
  50.  
  51. Be sure that the engine/transaxle assembly is free from all hoses, vacuum lines and electrical wires and connectors.
  52.  
  53. Remove the engine/transaxle assembly from under the vehicle.
  54.  

To install:

  1. Installation is the reverse of the removal procedure. Be sure to check and adjust all required fluid levels.
  2.  
  3. Reprogram the ECM engine idle characteristics. Be sure all electrical items are OFF.
  4.  
  5. Start the engine. Hold the idle speed at 3000 RPM-s in neutral until the radiator fan comes on or the temperature reached 194 degrees.
  6.  
  7. Let the engine idle for about five minutes with the throttle fully closed.
  8.  
  9. If the radiator fan comes on during the five minutes, do not count this toward the five minute programming time.
  10.  
  11. Reprogram the crankshaft position (CKP) pattern. Run the engine until the operating temperature reaches 176 degree. With the engine stopped clear the CKP pattern. Turn the ignition switch OFF. Turn the ignition switch ON and wait thirty seconds.
  12.  
  13. Road test the vehicle on a level surface. Decelerate the engine speed of 2500 rpm to 1000 rpm. If equipped with automatic transaxle use two Drive positions. If equipped with manual transaxle use first gear.
  14.  
  15. Stop the vehicle, but keep the engine running.
  16.  
  17. Check PULSAR F/B LEARN in the data list with the HDS. If not complete repeat the procedure. If complete, road test the vehicle on a level surface. Decelerate the engine speed of 5000 rpm to 3000 rpm. If equipped with automatic transaxle use two Drive positions. If equipped with manual transaxle use first gear.
  18.  
  19. Stop the vehicle, but keep the engine running.
  20.  
  21. Check PULSAR F/B LEARN in the data list with the HDS. If not complete repeat the procedure.
  22.  
  23. If completed, turn the ignition switch OFF. Turn the ignition switch ON, wait thirty seconds. The learning procedure is now complete.
  24.  
  25. Enter the antitheft codes for the radio and the navigation system. Set the clock.
  26.  
  27. Reprogram the power window control unit as follows.
  28.  
  29. Turn the ignition switch ON. Lower the window, all the way down. Open the driver-s side door.
  30.  
  31. Turn the ignition switch OFF. Push and hold the drivers window DOWN switch. Turn the ignition switch ON. Release the driver-s window DOWN switch. This must be done within five seconds.
  32.  
  33. Repeat the above step three more times. Wait one second.
  34.  
  35. Confirm that the AUTO UP and AUTO DOWN do not work. If they work repeat the procedure, paying close attention to the five second time limit
  36.  
  37. Move the driver-s window all the way down by holding the drivers window DOWN switch to the AUTO DOWN position.
  38.  
  39. Pull up and hold the driver-s window UP switch to the AUTO UP position until the window reaches the fully closed position. Hold the switch for one second.
  40.  
  41. Confirm that the power window master switch has been reset by using the driver-s window AUTO UP and DOWN function.
  42.  
  43. If the AUTO UP and DOWN feature is still not working, repeat the complete procedure, paying close attention to the five second time limit.
  44.  

2006 Models 2.0L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Note the radio security code and the radio presets.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Disconnect the negative battery cable, than the positive cable. Remove the hood support from the driver-s side of the vehicle. Lock the hood in the full up position.
  8.  
  9. Remove the battery. Remove the air cleaner assembly. Remove the cowl cover and undercover panel.
  10.  
  11. Disconnect the harness clamp. Remove the resonator unit.
  12.  
  13. Remove the battery cables from the under hood fuse/relay box. Remove the harness clamps. Remove the ECM /PCM control module cover. Remove the assembly retaining bolts. Disconnect the electrical connectors. Disconnect the engine wiring harness connector. Remove the harness clamps.
  14.  
  15. Remove the intake manifold cover. Remove the fuel line quick connect fitting cover. Disconnect the fuel feed hose. Remove the evaporative emission canister hose, power brake vacuum booster hoses and power steering hose clamp.
  16.  
  17. If equipped with manual transaxle, remove the bolts retaining the harness holder. Remove the harness clamp. Remove the shift cable. Remove the clutch slave cylinder and line bracket mounting bolt.
  18.  
  19. Remove the air cleaner housing bracket. Remove the drive belt. Remove the idler pulley base. Remove the radiator cap.
  20.  
  21. Raise and safely support the vehicle. Remove the front tires. Remove the splash shield. Drain the radiator. Drain the engine oil. Drain the transaxle fluid.
  22.  
  23. Disconnect the air fuel ratio (A/F) sensor connector. Remove the grommet and disconnect the oxygen sensor connector. Remove the three way catalytic converter.
  24.  
  25. Separate the stabilizer links. Separate the knuckles from the lower arms. Remove the driveshafts.
  26.  
  27. Remove the steering gearbox bracket. Remove the steering gearbox mounting bolt, stiffener mounting bolt and stiffener. Remove the harness clamp from the subframe.
  28.  
  29. Disconnect the air conditioning compressor clutch connector and remove the harness clamp. Remove the compressor assembly, without disconnecting the refrigerant lines. Lower the vehicle to the ground.
  30.  
  31. Remove the radiator. Remove the heater hoses. Attach the engine support tool (AAR-T-12566) to the vehicle.
  32.  
  33. Raise and support the vehicle safely. Remove the lower torque rod. Remove the lower radiator hose from the clamp. Remove the front mount retaining bolt.
  34.  
  35. Matchmark the subframe with the edge of the subframe stiffener. Attach special tool VSB02C000016 by hanging the belt over the front of the subframe. Secure the belt to the stop.
  36.  
  37. Raise the jack, line up the slots in the tool arms with the bolt holes on the corner of the jack base. Attach the four bolts.
  38.  
  39. Remove the subframe. Lower the vehicle to the ground. Remove the side engine mount bracket retaining bolt and nut. Remove the transaxle mount bracket and retaining bolt and nuts.
  40.  
  41. Attach a lifting device. Raise the engine/transaxle assembly up slightly. Remove the engine support tool.
  42.  
  43. Remove the side engine mount bracket. Remove the transaxle mounting bolt and nuts. Remove the ground cable.
  44.  
  45. Be sure that the engine/transaxle assembly is free from all hoses, vacuum lines and electrical wires and connectors.
  46.  
  47. Remove the engine/transaxle assembly from under the vehicle.
  48.  

To install:

  1. Installation is the reverse of the removal procedure. Be sure to check and adjust all required fluid levels.
  2.  
  3. Reprogram the ECM engine idle characteristics. Be sure all electrical items are OFF.
  4.  
  5. Start the engine. Hold the idle speed at 3000 RPM-s in neutral until the radiator fan comes on or the temperature reached 194 degrees.
  6.  
  7. Let the engine idle for about five minutes with the throttle fully closed.
  8.  
  9. If the radiator fan comes on during the five minutes, do not count this toward the five minute programming time.
  10.  
  11. Reprogram the crankshaft position (CKP) pattern. Run the engine until the operating temperature reaches 176 degree. With the engine stopped clear the CKP pattern. Turn the ignition switch OFF. Turn the ignition switch ON and wait thirty seconds.
  12.  
  13. Road test the vehicle on a level surface. Decelerate the engine speed of 2500 rpm to 1000 rpm. If equipped with automatic transaxle use two Drive positions. If equipped with manual transaxle use first gear.
  14.  
  15. Stop the vehicle, but keep the engine running.
  16.  
  17. Check PULSAR F/B LEARN in the data list with the HDS. If not complete repeat the procedure. If complete, road test the vehicle on a level surface. Decelerate the engine speed of 5000 rpm to 3000 rpm. If equipped with automatic transaxle use two Drive positions. If equipped with manual transaxle use first gear.
  18.  
  19. Stop the vehicle, but keep the engine running.
  20.  
  21. Check PULSAR F/B LEARN in the data list with the HDS. If not complete repeat the procedure.
  22.  
  23. If completed, turn the ignition switch OFF. Turn the ignition switch ON, wait thirty seconds. The learning procedure is now complete.
  24.  
  25. Enter the antitheft codes for the radio and the navigation system. Set the clock.
  26.  
  27. Reprogram the power window control unit as follows.
  28.  
  29. Turn the ignition switch ON. Lower the window, all the way down. Open the driver-s side door.
  30.  
  31. Turn the ignition switch OFF. Push and hold the drivers window DOWN switch. Turn the ignition switch ON. Release the driver-s window DOWN switch. This must be done within five seconds.
  32.  
  33. Repeat the above step three more times. Wait one second.
  34.  
  35. Confirm that the AUTO UP and AUTO DOWN do not work. If they work repeat the procedure, paying close attention to the five second time limit
  36.  
  37. Move the driver-s window all the way down by holding the drivers window DOWN switch to the AUTO DOWN position.
  38.  
  39. Pull up and hold the driver-s window UP switch to the AUTO UP position until the window reaches the fully closed position. Hold the switch for one second.
  40.  
  41. Confirm that the power window master switch has been reset by using the driver-s window AUTO UP and DOWN function.
  42.  
  43. If the AUTO UP and DOWN feature is still not working, repeat the complete procedure, paying close attention to the five second time limit.
  44.  

Prelude
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Secure the hood as far open as possible.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable, then the positive battery cable
     
    Radiator cap
     

  6.  
  7. Raise and safely support the vehicle. Remove the front wheels and the engine splash shield.
  8.  
  9. Drain the engine coolant into a sealable container.
  10.  
  11. Drain the transaxle fluid into a sealable container. Install the drain plug with a new gasket.
  12.  
  13. Lower the vehicle to a working level.
  14.  
  15. Remove or disconnect the following:

    Air intake duct and the air cleaner case
     
    PAIR vacuum tank and bracket
     
    Battery and the battery base
     
    Battery cable and starter cable harnesses from the body
     

  16.  
  17. Relieve the pressure from the fuel system.
    CAUTION
    The fuel injection system remains under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  18.  
  19. Remove or disconnect the following:

    Fuel feed hose from the fuel rail and the fuel return line from the fuel pressure regulator
     
    Injector resistor connector on the left side of the engine compartment
     
    Throttle cable by loosening the locknut, then slip the cable end out of the throttle linkage. Take care not to bend the cable when removing it. Always replace any kinked cable with a new one.
     
    Engine wiring harness connectors, terminal, and clamps on the right side of the engine
     
    Power cable from the under-hood fuse/relay box
     
    Brake booster vacuum hose and emissions control vacuum tubes from the intake manifold
     
    Cruise control actuator electrical connector and vacuum tube, then the actuator
     
    Engine ground cable from the body side
     
    Power steering pump drive belt, then the pump
     
    Air conditioning condenser fan, then install a protector plate on the radiator
     
    Alternator mounting bolt, nut, and adjusting nut, then the alternator drive belt
     
    Air conditioning compressor electrical connector
     
    Compressor without disconnecting the air conditioning hoses. Support the compressor with a strong wire out of the way.
     
    Upper and lower radiator hoses, and the heater hoses from the engine
     
    Transaxle ground cable
     
    Cooler hoses, if equipped with an automatic transaxle
     

  20.  
  21. If equipped with a manual transaxle perform the following:
    1. Disconnect the shift cable and the select cable from the transaxle. Do not bend the cables when removing them. Replace any kinked cable with a new one.
    2.  
    3. Remove the clutch slave cylinder and the pipe/hose assembly. Do not depress the clutch pedal once the slave cylinder has been removed.
    4.  
    5. Remove the clutch damper assembly.
    6.  

  22.  
  23. Remove or disconnect the following:

    Vehicle Speed/Power Steering Speed (VSS/PSS) sensor assembly. Do not disconnect the hoses
     
    Nuts attaching the exhaust pipe to the exhaust manifold and the catalytic converter
     
    Bolts from the exhaust pipe hanger, then the exhaust pipe and discard the gaskets
     

  24.  
  25. If equipped with an automatic transaxle, remove the shift cable cover, then disconnect the shift cable. Do not bend the cable and replace the cable if it becomes kinked.
  26.  
  27. Remove or disconnect the following:

    Left and the right side damper forks
     
    Lower ball joints from the lower control arms
     

  28.  
  29. Pry the halfshafts from the transaxle. Cover the inner CV-joints with plastic bags to protect them.
  30.  
  31. Swing the halfshafts under the fender out of the way.
  32.  
  33. Attach an engine hoist to the engine lifting points and raise the hoist to remove all slack from the chain.
  34.  
  35. Remove or disconnect the following:

    Rear engine mount bracket
     
    Front engine mount bracket
     
    Left side engine mount
     
    Transaxle mount and the mount bracket
     

  36.  
  37. Check that the engine is completely free of vacuum hoses, fuel and coolant hoses, and electrical wiring.
  38.  
  39. Slowly raise the engine approximately 6 in. (150mm). Check once again that all hoses and wires have been disconnected from the engine.
  40.  
  41. Raise the engine all the way and remove it from the vehicle.
  42.  
  43. Remove the transaxle.
  44.  
  45. If equipped with a manual transaxle, remove the clutch cover (pressure plate) and clutch disc.
  46.  
  47. Mount the engine on an engine stand, making sure the mounting bolts are tight. If an engine stand is not available, support the engine in an upright position with blocks. Never leave an engine hanging from a lift or hoist.
  48.  

To install:

  1. Install or connect the following:
    NOTE
    When installing the engine mounts and vibration dampers in the following steps, they must be tightened to the correct tension in the correct order if they are to damp vibration properly.



    Clutch disc and pressure plate to the flywheel for manual transaxle vehicles
     
    Transaxle
     
    Engine into position and lower it into the car, aligning the mounts and bushings.
     



    Side engine mount and the through-bolt. Do not tighten the through-bolt at this time
     
    Nut and bolt attaching the side mount to the engine: 40 ft. lbs. (55 Nm)
     
    Transaxle mount and through-bolt. Do not tighten the through-bolt at this time
     
    Rear engine mount and new bolts attaching the mount to the engine: 40 ft. lbs. (55 Nm)
     
    New rear engine mount through-bolt: 47 ft. lbs. (65 Nm)
     
    Front mount and the 3 bolts attaching the mount to the engine assembly, only snug the bolts in place
     
    New through-bolt to the front mount: 47 ft. lbs. (65 Nm)
     
    Nuts to the transaxle mount: 28 ft. lbs. (39 Nm)
     

  2.  
  3. Tighten the side engine mount through-bolt to 47 ft. lbs. (65 Nm).
  4.  
  5. Tighten the transaxle mount through-bolt to 47 ft. lbs. (65 Nm).
  6.  
  7. Tighten the 3 bolts attaching the front mount to the engine to 28 ft. lbs. (39 Nm).
  8.  
  9. Remove the hoist equipment from the engine.
  10.  
  11. Install or connect the following:

    New spring clips to the inner CV-joints
     
    Halfshafts into the transaxle. Be sure that the inner joint spring clips click into place
     
    Lower ball joints to the lower control arms. Tighten the nuts to 36-43 ft. lbs. (50-60 Nm). Install a new cotter pin to the ball joint stud.
     

  12.  
  13. Using new self-locking bolts, attach the damper forks to the struts and tighten to 32 ft. lbs. (44 Nm). Tighten the new nut and bolt attaching the damper fork to the lower control arm to 47 ft. lbs. (65 Nm).
  14.  
  15. If equipped with an automatic transaxle, connect the shift cable to the transaxle. Install a new lockwasher and tighten the attaching bolt to 84 inch lbs. (10 Nm). Install the shift cable cover. Tighten the shift cable cover attaching bolts to 13 ft. lbs. (18 Nm).
  16.  
  17. Install or connect the following:

    Exhaust pipe with new gaskets
     
    New nuts attaching the exhaust pipe to the exhaust manifold: 40 ft. lbs. (55 Nm)
     
    New nuts attaching the exhaust pipe to the catalytic converter: 25 ft. lbs. (34 Nm)
     
    New attaching bolts to the exhaust pipe hanger: 13 ft. lbs. (18 Nm)
     
    VSS/PSS, connect the electrical connector, and tighten the mounting bolt to 13 ft. lbs. (18 Nm)
     

  18.  
  19. If equipped with a manual transaxle perform the following:
    1. Install the clutch damper assembly and tighten the attaching bolts to 16 ft. lbs. (22 Nm).
    2.  
    3. Install the clutch slave cylinder and the pipe/hose assembly and tighten the slave cylinder mounting bolts to 16 ft. lbs. (22 Nm).
    4.  
    5. Connect the shift cable and the select cable to the transaxle. Adjust the shift cable and select cable.
    6.  

  20.  
  21. Install or connect the following:

    Cooler hoses, if equipped with an automatic transaxle
     
    Transaxle ground cable
     
    Upper and lower radiator hoses and heater hoses to the engine
     
    Air conditioning compressor, connect the electrical connector. Tighten the mounting bolts to 16 ft. lbs. (22 Nm).
     
    Alternator drive belt, then adjust
     

  22.  
  23. Remove the protector plate from the radiator and install the air conditioning condenser fan.
  24.  
  25. Install or connect the following:

    Power steering pump and drive belt. Adjust the drive belt tension, then tighten the attaching nuts and bolts to 16 ft. lbs. (22 Nm).
     
    Engine ground cable to the body
     
    Cruise control actuator, electrical connector and vacuum tube. Tighten the mounting bolts to 84 inch lbs. (10 Nm)
     
    Brake booster vacuum hose and the emissions control vacuum tubes to the intake manifold
     
    Engine wiring harness connectors, terminal, and clamps
     
    Throttle cable, then adjust
     
    Injector resistor connector on the left side of the engine compartment
     
    Fuel return hose to the regulator
     
    Fuel feed hose to the fuel rail with new washers. Tighten the cap nut to 16 ft. lbs. (22 Nm)
     
    Battery and starter cables to the body
     
    Battery base and the battery. Tighten the battery base attaching bolts to 16 ft. lbs. (22 Nm)
     
    PAIR vacuum tank and bracket. Tighten the mounting bolts to 96 inch lbs. (10 Nm)
     
    Air cleaner duct and housing
     
    Engine splash shield and the front wheels
     

  26.  
  27. Lower the vehicle.
  28.  
  29. Fill the engine with oil and the transaxle with fluid.
  30.  
  31. Fill and bleed the air from the cooling system.
  32.  
  33. Connect the positive, then the negative battery cable and enter the radio security code.
  34.  
  35. Switch the ignition ON but do not engage the starter. The fuel pump should run for approximately 2 seconds, building pressure within the lines. Switch the ignition OFF , then ON 2 or 3 more times to build full system pressure. Check for fuel leaks.
  36.  
  37. Start the engine, allowing it to idle. Check the hoses and lines carefully for any sign of leakage.
  38.  
  39. Check the timing and idle speed.
  40.  
  41. After the engine has warmed up fully and the fan(s) have come on at least once, recheck the engine for fluid leaks. Switch the engine OFF.
  42.  
  43. Adjust the belts and throttle cable as necessary.
  44.  
  45. If equipped with 4WS, start the engine and turn the steering wheel lock-to-lock to reset the 4WS control unit.
  46.  
  47. Road test the vehicle, then loosen and retighten the 3 bolts attaching the front engine mount to the engine. Tighten the bolts to 28 ft. lbs. (39 Nm).
  48.  

S2000
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following: BatteryFront wheelsTransmissionEngine Control Module (ECM) connectors and the main wire harness connector. Pass the connectors through the cowl panel.Vacuum tankThrottle cableElectrical Power Steering (EPS) control unitBattery cable at the main under-hood fuse/relay boxBattery cable at the auxiliary fuse boxGround cable and harness clampsFuel linesBrake booster vacuum lineEvaporative Emissions (EVAP) canister hoseFront motor mount and bracketHeater hosesRadiator hosesLeft motor mountRight motor mount bracket

    Battery
     
    Front wheels
     
    Transmission
     
    Engine Control Module (ECM) connectors and the main wire harness connector. Pass the connectors through the cowl panel.
     
    Vacuum tank
     
    Throttle cable
     
    Electrical Power Steering (EPS) control unit
     
    Battery cable at the main under-hood fuse/relay box
     
    Battery cable at the auxiliary fuse box
     
    Ground cable and harness clamps
     
    Fuel lines
     
    Brake booster vacuum line
     
    Evaporative Emissions (EVAP) canister hose
     
    Front motor mount and bracket
     
    Heater hoses
     
    Radiator hoses
     
    Left motor mount
     
    Right motor mount bracket
     

  8.  
  9. Carefully raise the engine out of the vehicle.
  10.  

To install:

  1. Installation is the reverse of the removal procedure, while using the following torque values: Right motor mount bracket bolts: 28 ft. lbs. (38 Nm)Motor mount nuts: 40 ft. lbs. (54 Nm)Front motor mount bolts: 16 ft. lbs. (22 Nm)

    Right motor mount bracket bolts: 28 ft. lbs. (38 Nm)
     
    Motor mount nuts: 40 ft. lbs. (54 Nm)
     
    Front motor mount bolts: 16 ft. lbs. (22 Nm)
     

  2.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Note the radio security code and the radio presets.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Disconnect the negative battery cable, than the positive cable. Remove the hood support from the driver-s side of the vehicle. Lock the hood in the full up position.
  8.  
  9. Remove the battery.
  10.  
  11. Raise and support the vehicle safely. Drain the engine oil.
  12.  
  13. Remove the transmission. Lower the vehicle.
  14.  
  15. On 2001-05 vehicles, disconnect the electronic control module (ECM) connectors from the ECM.
  16.  
  17. On 2006 vehicles, disconnect the dashboard wiring harness connector.
  18.  
  19. On 2001-05 vehicles, Remove the vacuum tank and throttle cable assembly.
  20.  
  21. Remove the electrical power steering (EPS) retaining bolts. Remove the control unit from its mounting.
  22.  
  23. Remove the battery cable from the main under hood fuse/relay box. Remove the harness clamps.
  24.  
  25. Remove the battery cable from the auxiliary under hood fuse box. Remove the ground cable and harness clamps.
  26.  
  27. Remove the harness retaining grommet from its mounting and pull out the ECM connectors.
  28.  
  29. Remove the radiator cap. Raise and safely support the vehicle. Drain the engine coolant.
  30.  
  31. Remove the engine stop bracket cushion and stop bracket. Lower the vehicle.
  32.  
  33. Disconnect and remove the heater hoses. Remove the lower radiator hose. Remove the upper radiator hose.
  34.  
  35. On 2001-05 vehicles, remove the fuel feed hose, fuel return hose and brake booster vacuum hose.
  36.  
  37. On 2006 vehicles, Remove the intake manifold cover. Remove the quick connect fitting cover, then disconnect the fuel feed hose and brake booster vacuum hose.
  38.  
  39. Disconnect the evaporative emission (EVAP) canister hose.
  40.  
  41. Properly attach the engine lifting device.
  42.  
  43. Remove the support nut from the left side engine mount bracket. Remove the support nut and the four mounting bolts. Remove the right side engine mount bracket.
  44.  
  45. Raise the engine. Check to insure that no wires, hoses etc are attached. Remove the engine from the vehicle.
  46.  

To install:

  1. Installation is the reverse of the removal procedure, while using the following torque values:

    Right motor mount bracket bolts: 28 ft. lbs. (38 Nm)
     
    Motor mount nuts: 40 ft. lbs. (54 Nm)
     
    Front motor mount bolts: 16 ft. lbs. (22 Nm)
     

  2.  
  3. Reprogram the ECM engine idle characteristics. Be sure all electrical items are OFF.
  4.  
  5. Start the engine. Hold the idle speed at 3000 RPM-s in neutral until the radiator fan comes on or the temperature reached 176 degrees.
  6.  
  7. Let the engine idle for about five minutes with the throttle fully closed.
  8.  
  9. If the radiator fan comes on during the five minutes, do not count this toward the five minute programming time.
  10.  
  11. Set the clock.
  12.  

 
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