Engine: Service and Repair

WARNING:
^ Make sure jacks and safety stands are placed properly and hoist brackets are attached to the correct positions on the engine.
^ Make sure the car will not roll off stands and fall while you are working under it.

CAUTION:
^ Use fender covers to avoid damaging painted surfaces.
^ Unspecified items are common.
^ Unplug the wiring connectors carefully while holding the connector portion to avoid damage.
^ Mark all wiring and hoses to avoid Disconnection. Also, be sure that they do not contact other wiring or hoses, or interfere with other parts.

NOTE:
^ The original radio has a coded theft protection circuit. Be sure to get the customer's code number before:
- disconnecting the battery.
- removing the No. 32 (7.5 A) fuse from the under-hood fuse/relay box.
- removing the radio.
^ After service, reconnect power to the radio and turn it on.
^ When the word "CODE" is displayed, enter the customer's 5-digit code to restore radio operation.

1. Disconnect the battery negative terminal first, then the positive terminal.
2. Fix the engine hood in a vertical position.
^ Do not remove the engine hood.
3. Remove the radiator cap.
^ Use care when removing the radiator cap to avoid scalding by hot engine coolant or steam.





4. Raise the hoist to full height. Remove the front tires/ wheels and the engine splash shield.
5. Drain the engine coolant. Refer to Cooling System.
^ Loosen the drain plug in the radiator lower tank.
6. Drain the transmission oil/fluid. Reinstall the drain plug using a new washer.
7. Drain the engine oil. Reinstall the drain plug using a new washer.

CAUTION: Do not overtighten the drain plug.

8. Lower the hoist. Secure the hood as far open as possible.
9. Remove the under hood ABS fuse/relay box.
10. Remove the intake air duct and air cleaner housing.





^ Disconnect the IAT sensor connector, then remove the intake air duct and air cleaner housing.
connector, then remove the air cleaner housing.
11. Relieve fuel pressure by loosening the service bolt on the fuel filter about one turn. Refer to Powertrain Management.

WARNING: Do not smoke while working on the fuel system. Keep open flame or spark away from the work area. Drain fuel only into an approved container.

CAUTION:
^ Before disconnecting any fuel line, the fuel pressure should be relieved as described above.
^ Place a shop towel over the fuel filter to prevent pressurized fuel from spraying over the engine.





12. Remove the evaporative emission (EVAP) control canister hose and fuel feed hose.





13. Remove the brake booster vacuum hose, fuel return hose and vacuum hose.
14. Remove the throttle cable by loosening the locknut, then slip the cable end out of the accelerator linkage.





NOTE:
^ Take care not to bend the cable when removing it. Always replace any kinked cable with a new one.
^ Adjust the throttle cable when installing. Refer to Powertrain Management.





15. Disconnect the engine wire harness connector on the left side of the engine compartment.
16. Disconnect the engine wire harness connector on the right side of the engine compartment.





17. Disconnect the battery cables from the under-hood fuse/relay box and battery positive terminal.
18. Remove the ground cable.





19. Remove the mounting bolts and adjusting bolt, then remove the power steering (P/S) pump belt and pump.

NOTE: Do not disconnect the P/S hoses.

20. Remove the air conditioning (A/C) compressor belt.





^ Loosen the idler pulley center nut and adjusting bolt, then remove the A/C compressor belt.





21. Remove the transmission ground cable and the automatic transmission fluid (ATF) cooler hoses.





22. Remove the clutch slave cylinder and pipe/hose assembly (Manual Transmission).

NOTE:
^ Do not disconnect the pipe/hose assembly.
^ Do not operate the clutch pedal once the slave cylinder has been removed.
^ Take care not to bend the pipe.





23. Remove the upper and lower radiator hoses and heater hoses.
24. Raise the hoist full height.





25. Remove exhaust pipe A.





26. Remove the A/C compressor.

NOTE: Do not disconnect the A/C hoses.





27. Remove the shim cable (Automatic Transmission).

NOTE:
^ Take care not to bend the cable when removing it. Always replace any kinked cable with new one.
^ Adjust the shift cable when installing. Refer to Powertrain Management.





28. Remove the shift rod and extension rod (Manual Transmission).
29. Remove the damper forks. Refer to Steering and Suspension.
30. Disconnect the suspension lower arm ball joints. Refer to Steering and Suspension.





31. Remove the driveshafts.

NOTE: Coat all precision-finished with clean engine oil. Tie plastic bags over the driveshaft ends.

32. Lower the hoist.





33. Attach the chain hoist to the engine.





34. Remove the left and right front engine mount and brackets.





35. Remove the rear engine mounting bracket.
36. Remove the cruise control actuator.





37. Remove the side engine mount.





38. Remove the transmission mount nuts. Loosen the mount bolt and pivot the transmission side mount out of the way.
39. Raise the chain hoist to remove all slack from the chain.
40. Check that the engine is completely free of vacuum hoses, fuel and coolant hoses, and electrical wiring.
41. Slowly raise the engine approximately 6 inch (150 mm). Check once again that all hoses and wires have been disconnected from the engine.
42. Raise the engine all the way and remove it from the car.
43. Install the engine in the reverse order of removal.














NOTE:
^ After the engine is in place:
^ Torque the engine mounting bolts in the sequence shown.

CAUTION: Failure to tighten the bolts in the proper sequence can cause excessive noise and vibration, and reduce bushing life; check that the bushings are not twisted or offset.

^ Check that the spring clip on the end of each driveshaft clicks into place.

CAUTION: Use new spring clips.

^ Bleed air from the cooling system with the heater valve open.
^ Adjust the throttle cable tension.
^ Check the clutch pedal free play (Manual Transmission).
^ Check that the transmission shifts into gear smoothly.
^ Adjust the tension of the following drive belts.
- Alternator belt. Refer to Starting and Charging.
- Power steering pump belt. Refer to Steering and Suspension.
- Air conditioning compressor belt. Refer to Heating and Air Conditioning.
^ Clean battery posts and cable terminals with sandpaper, assemble, then apply grease to prevent corrosion.
^ Inspect for fuel leakage.
- After assembling fuel line parts, turn on the ignition switch (do not operate the starter) so that the fuel pump operates for approximately two seconds and the fuel line is pressurized. Repeat this operation two or three times and check for fuel leakage at any point in the fuel line.