Engine: Service and Repair

ENGINE

- Tools Required
- KM-470-B Angular Torque Gauge

Removal Procedure

Important: On vehicles equipped with a manual transaxle, the manual transaxle must be removed before the engine is removed. Refer to Transmission and Drivetrain.





1. Remove the fuel pump fuse.
2. Start the engine. Crank the engine for 10 seconds after it stalls to rid the fuel system of fuel pressure.
3. Remove the hood.
4. Drain the engine oil.
5. Disconnect the negative battery cable.
6. Disconnect and separate the positive battery cable.





7. Disconnect the negative battery cable from the vehicle frame.
8. Discharge the air conditioning (A/C) system, if equipped. Refer to Heating and Air Conditioning.
9. Disconnect the intake air temperature (1AT) sensor connector.





10. Remove the air intake tube from the throttle body and air filter housing.
11. Disconnect the breather tubes from the valve cover.
12. Remove the right front wheel.
13. Remove the right front splash shield.





14. Remove the A/C compressor drive belt, if equipped.
15. Remove the alternator drive belt.
16. Remove the power steering pump pulley bolts.
17. Remove the power steering pump pulley.
18. Drain the engine coolant. Refer to Cooling System.
19. Remove the cooling system radiator and the engine cooling fans. Refer to Cooling System.
20. Disconnect the upper radiator hose from the thermostat housing.
21. Disconnect the power steering return hose from the power steering pump, if equipped. Refer to Steering.
22. Disconnect the power steering pressure hose from the power steering pump, if equipped. Refer to Steering.





23. Disconnect the electrical connector at the electronic ignition (EI) system ignition coil and the powertrain control module / engine control module (PCM / ECM) ground terminal at the intake manifold and at the starter motor.
24. Disconnect the oxygen sensor connector.
25. Disconnect the fuel injector harness connectors.





26. Disconnect the idle air control (IAC) valve connector.
27. Disconnect the throttle position sensor (TPS) connector.
28. Disconnect the engine coolant temperature (ECT) sensor connector.
29. Disconnect the coolant temperature sensor (CTS) connector.
30. Disconnect the alternator voltage regulator connector.
31. Disconnect the camshaft position (CMP) sensor.
32. Disconnect all of the necessary vacuum lines including the brake booster vacuum hose.





33. Disconnect the fuel return line at the fuel pressure regulator.
34. Disconnect the fuel feed line at the fuel rail.
35. Disconnect the throttle cable from the throttle body and the intake manifold bracket.





36. Disconnect the surge tank coolant hose at the throttle body.
37. Disconnect the heater outlet hose at the coolant pipe.
38. Disconnect the heater inlet hose from the cylinder head.
39. Disconnect the surge tank coolant hose from the coolant pipe.
40. Disconnect the lower radiator hose from the coolant pipe.
41. Disconnect the starter solenoid "S" terminal wire.
42. Remove the A/C compressor hose assembly retaining bolt.
43. Disconnect the A/C compressor hose assembly from the compressor.
44. Disconnect the electrical connector at the A/C compressor coil.
45. Remove the A/C compressor mounting bolts.





46. Remove the A/C compressor.
47. Remove the A/C compressor mounting bracket bolts from the engine block.
48. Remove the A/C compressor mounting bracket.





49. Remove the auxiliary catalytic converter nuts from the exhaust manifold studs and the bolts at the bracket.





50. Remove the nuts that secure the front muffler pipe to the main catalytic converter.
51. Remove both catalytic converters.
52. Remove the crankshaft pulley bolt.
53. Remove the crankshaft pulley.
54. Disconnect the vacuum lines at the evaporative (EVAP) emission canister purge solenoid.
55. Disconnect the electrical connector at the EVAP emissions charcoal canister purge solenoid.





56. Disconnect the electrical connector at the oil pressure switch.
57. Disconnect the crankshaft position (CKP) sensor and the knock sensor connectors.
58. Remove the (CKP) sensor retaining bolt.
59. Remove the CKP sensor.
60. Remove the right transaxle brace bolts from the transaxle.





61. Remove the flywheel or flexible plate inspection cover bolts.
62. Remove the flywheel or flexible plate inspection cover.





63. Remove the transaxle torque converter bolts on vehicles with an automatic transaxle.
64. Remove the transaxle bell housing bolts.
65. Support the transaxle with a floor jack.
66. Install the engine lifting device.





67. Disconnect the right engine mount bracket from the engine mount by removing the retaining bolts.
68. Remove the right engine mount bracket from the engine block.
69. Separate the engine block from the transaxle.
70. Remove the engine.

Installation Procedure
1. Install the engine into the engine compartment.
2. Align the engine alignment pins to the transaxle.





3. Install the transaxle bell housing bolts.
Tighten the transaxle bell housing bolts to 75 Nm (55 ft. lbs.).
4. Install the right engine mount bracket to the engine block.
5. Install the right engine mount bracket retaining bolts.
Tighten the engine mount bracket retaining bolts to 60 Nm (44 ft. lbs.).





6. Connect the right engine mount bracket to the engine mount by installing the two retaining bolts.
Tighten the engine mount-to-engine mount bracket retaining bolts to 60 Nm (44 ft. lbs.).
7. Remove the floor jack used for support of the transaxle.
8. Remove the engine lifting device.





9. Install the transaxle torque converter bolts on vehicles equipped with an automatic transaxle.
Tighten the transaxle torque converter bolts to 65 Nm (48 ft. lbs.).
10. Install the flywheel or flexible plate inspection cover.
11. Install the flywheel or flexible plate inspection cover bolts.
Tighten the flywheel inspection cover bolts to 12 Nm (106 inch lbs.) or the flexible plate inspection cover bolts to 10 Nm (89 inch lbs.).





12. Install the right transaxle brace bolts to the transaxle.
Tighten the transaxle brace bolts to 40 Nm (30 ft. lbs.).
13. Connect the vacuum lines at the EVAP charcoal canister purge solenoid.
14. Connect the electrical connector to the EVAP emission canister purge solenoid.
15. Connect the oil pressure switch connector.
16. Install the crankshaft pulley.





17. Install the crankshaft pulley bolt.
Tighten the crankshaft pulley bolt to 95 Nm (70 ft. lbs.) using a torque wrench. Using the angular torque gauge KM-470-B, tighten the crankshaft pulley bolt 30 degrees plus 15 degrees.
18. Install the CKP sensor and the CKP sensor retaining bolt.
Tighten the crankshaft position sensor retaining bolt to 10 Nm (89 inch lbs.).
19. Connect the CKP sensor and the knock sensor connectors.





20. Install the catalytic converters.
Tighten the auxiliary catalytic converter-to-exhaust manifold nuts and the bolts at the bracket to 40 Nm (30 ft. lbs.).
Tighten the front muffler-to-main catalytic converter nuts to 30 Nm (22 ft. lbs.).
21. Connect the power steering pressure hose, if equipped. Refer to Steering.
22. Connect the power steering return hose, if equipped. Refer to Section 6A, Power Steering System.
23. Install the A/C compressor mounting bracket, if equipped.





24. Install the A/C compressor mounting bracket bolts, if equipped.
Tighten the A/C compressor mounting bracket bolts to 50 Nm (37 ft. lbs.).





25. Install the A/C compressor, if equipped.
26. Install the A/C compressor mounting bolts, if equipped.
Tighten the A/C compressor mounting bolts to 27 Nm (20 ft. lbs.).
27. Connect the A/C compressor coil connector, if equipped.
28. Install the alternator drive belt.





29. Install the A/C compressor drive belt, if equipped.
30. Connect the A/C compressor hose assembly and the A/C compressor hose assembly retaining bolt, if equipped.
Tighten the A/C compressor hose assembly retaining bolt to 33 Nm (24 ft. lbs.).
31. Install the power steering pump pulley, if equipped.
32. Install the power steering pump pulley bolts, if equipped.
Tighten the power steering pump pulley bolts to 25 Nm (18 ft. lbs.).
33. Install the right front splash shield.
34. Install the right front wheel.
35. Connect the fuel feed line to the fuel rail.





36. Connect the fuel return line to the fuel pressure regulator.
37. Connect all of the necessary vacuum lines including the brake booster vacuum hose.
38. Connect the oxygen sensor connector.
39. Connect the starter solenoid "S" terminal wire.
40. Connect the alternator voltage regulator connector.





41. Connect the CTS connector.
42. Connect the ECT sensor connector.
43. Connect the TPS connector.
44. Connect the IAC valve connector.
45. Connect the CMP sensor.
46. Connect the fuel injector harness connectors.
47. Connect the electrical connector at the EI system ignition coil and the PCM / ECM ground terminal at the intake manifold and the starter motor.





48. Install the air intake tube between the throttle body and the air filter housing.
49. Connect the breather tubes to the valve cover.
50. Connect the IAT sensor connector.
51. Install the cooling system radiator and the engine cooling fans. Refer to Cooling System.
52. Connect the lower radiator hose to the coolant pipe.
53. Connect the upper radiator hose to the thermostat housing.





54. Connect the heater inlet hose to the cylinder head.
55. Connect the heater outlet hose to the coolant pipe.
56. Connect the coolant surge tank hose to the coolant pipe.
57. Connect the surge tank coolant hose to the throttle body.
58. Connect the throttle cable to the throttle body and the intake manifold bracket.
59. Install the fuel pump fuse.
60. Connect the negative battery cable to the vehicle frame.





61. Connect the negative battery cable.
62. Connect and assemble the positive battery cable.
63. Refill the engine crankcase with engine oil.
64. Refill the engine coolant system. Refer to Cooling System.
65. Bleed the power steering system, if equipped. Refer to Steering.
66. Refill the A/C refrigerant system, if equipped. Refer to Heating and Air Conditioning.
67. Install the hood.