Engine: Service and Repair

Engine Removal/Installation

Removal

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 vehicle will not roll off stands and fall while you are working under it.

CAUTION:
- Use fender covers to avoid damaging painted surfaces.
- To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
- Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring or hoses, or interfere with other parts.




1. Turn off the manual shut-off valve.
2. To reduce fuel pressure in the lines, start the engine and run it until it stalls.
3. Secure the hood as far open as possible.
4. Disconnect the battery negative terminal first, then the positive terminal.




5. Disconnect the battery cables from the under-hood fuse/relay box and remove the harness clamps.




6. Remove the battery and battery base.
7. Disconnect the connectors from the PCM.




8. Disconnect the main wire harness connector.




9. Disconnect the intake air temperature (IAT) sensor connector, then remove the intake air duct and air cleaner assembly.




10. Disconnect the engine wire harness connectors on the left side of the engine compartment.
11. Disconnect the fuel pressure regulator shut-off solenoid valve connector and fuel pressure sensor connector, then remove the wire harness clamps.




12. Remove the nuts securing the grommet, then pull out the PCM connectors.




13. Remove the brake booster vacuum hose and vacuum hoses.




14. Remove the fuel feed hose.




15. Remove the throttle cable by loosening the lockout, 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.




16. Remove the mounting bolt and lock bolt, then remove the power steering (P/S) pump belt and pump.

NOTE: Do not disconnect the P/S hoses.




17. Loosen the idler pulley center nut and adjusting bolt, then remove the air conditioning (A/C) compressor belt.




18. Remove the transmission ground cable and the hose clamp.




19. Disconnect the power steering pressure (PSP) switch connector, and remove the wire harness clamp.
20. Remove the radiator cap.

WARNING: Use care when removing the radiator cap to avoid scalding by hot coolant or steam.

21. Raise the hoist to full height.
22. Remove the front tires/wheels.




23. Remove the splash shield.
24. Loosen the drain plug in the radiator and, drain the engine coolant.
25. Drain the automatic transmission fluid (ATF). Reinstall the drain plug using a new washer.
26. Drain the engine oil. Reinstall the drain bolt using a new washer.




27. Remove the A/C compressor.

NOTE: Do not disconnect the A/C hoses.




28. Remove the shift cable.

NOTE:
- Take care not to bend the cable when removing it. Always replace any kinked cable with a new one.
- Adjust the shift cable when installing.




29. Remove exhaust pipe A.
30. Remove the damper forks.
31. Disconnect the suspension lower arm ball joints.
32. Remove the driveshafts.
33. Lower the hoist.




34. Remove the upper and lower radiator hoses and the heater hoses.




35. Remove the ATF cooler hoses.




36. Attach the chain hoist to the engine.




37. Remove the left and right front mounts and brackets.




38. Remove the rear mount bracket.




39. Remove the upper bracket.




40. Remove the transmission mount bracket, then remove the transmission mount.
41. Check that the engine/transmission is completely free of vacuum hoses, fuel and coolant hoses and electrical wiring.
42. Slowly raise the engine approximately 150 mm (6 in). Check once again that all hoses and wires are disconnected from the engine/transmission.
43. Raise the engine all the way, and remove it from the vehicle.




Installation

Engine Installation:
Install the engine in the reverse order of removal. Reinstall the mount bolts/nuts in the following sequence. Failure to follow these procedures may cause excessive noise and vibration, and reduce bushing life.




1. Install the transmission mount and bracket, then tighten the transmission mount bolts. Do not tighten the nuts on the transmission mount bracket.




2. Install the upper bracket, then tighten the nuts in the numbered sequence as shown ((1) - (2)).




3. Install the rear mount bracket, then tighten the bolts in the numbered sequence shown ((1) - (2)).




4. Tighten the bolt/nuts on the transmission mount bracket in the numbered sequence shown ((1) - (2)).




5. Tighten the bolts on the right front mount/bracket in the numbered sequence shown ((1) - (2)).




6. Tighten the bolts/nut on the left front mount in the numbered sequence shown ((1) - (2)).




7. Perform the following:
- Clean the areas where the driveshaft(s) and the intermediate shaft contact the transmission (differential) thoroughly with solvent or carburetor cleaner, and dry with compressed air.
- Check that the set rings on the ends of the drive-shaft and intermediate shaft click into place

CAUTION: Use new set rings.

- Adjust the shift cable.
- Adjust the throttle cable.
- Adjust the cruise control cable.
- Refill the engine with engine oil.
- Refill the transmission with fluid.
- Bleed air from the cooling system with the heater valve open.
- Clean the battery posts and cable terminals with sandpaper, assemble them, then apply grease to prevent corrosion.