Engine: Service and Repair
ENGINE ASSEMBLY
Removal and Installation
WARNING:
^ Situate vehicle on a flat and solid surface.
^ Place chocks at front and back of rear wheels.
^ For engine not equipped with engine slingers, attach proper slingers and bolts described in PARTS CATALOG.
CAUTION:
^ Always be careful to work safely, avoid forceful or uninstructed operations.
^ Do not start working until exhaust system and engine coolant are cool enough.
^ If items or work required are not covered by the engine section, refer to the applicable sections.
^ Always use the support point specified for lifting.
^ Use either 2-pole lift or separate type lift as best you can. If board-on lift is used for unavoidable reasons, support at the rear axle jacking point with transmission jack or similar tool before starting work, in preparation for the backward shift of center of gravity.
^ For supporting points for lifting and jacking point at rear axle, refer to GI-40, "Garage Jack and Safety Stand". Garage Jack and Safety Stand
REMOVAL
Outline
At first, remove engine and transmission assembly with suspension member downward. Then separate engine from transmission.
Preparation
1. Release fuel pressure.
2. Disconnect both battery cables.
3. Remove the following parts:
^ Engine cover
^ Front wiper arm and cowl top cover
^ Undercover
^ Drive belts
^ Front road wheels and tires
4. Drain engine coolant from radiator.
5. Remove air cleaner case and air duct.
6. Discharge refrigerant from A/C circuit.
7. Remove radiator cooling fan assembly, reservoir tank and hoses.
Engine Room
1. Disconnect heater hose at engine-side, and fit a plug onto hose end to prevent engine coolant leak.
2. Disconnect ground cable (between vehicle to left cylinder head).
3. Disconnect battery positive cable harness at vehicle side and temporarily fasten it on engine.
4. Disconnect A/C piping from A/C compressor, and temporarily fasten it on vehicle with a rope.
5. Remove engine room harness connectors as shown in the figure.
6. Disconnect two body ground cables.
7. Disconnect brake booster vacuum hose.
8. Disconnect fuel feed hose (with damper) and EVAP hose.
CAUTION: Fit plugs onto disconnected hoses to prevent fuel leak.
9. Remove reservoir tank of power steering oil pump, and piping from vehicle, and temporarily secure them on engine.
CAUTION: When temporarily securing, keep the reservoir tank upright to avoid a fluid leak.
Passenger Room Side
Follow procedure below to disconnect engine room harness connectors at passenger room side, and temporarily secure them on engine.
1. Remove passenger-side kicking plate, dash side finisher, and glove box.
2. Disconnect engine room harness connectors at unit sides TCM (A/T models), ECM and other.
3. Disengage intermediate fixing point. Pull out engine room harnesses to engine room side, and temporarily secure them on engine.
CAUTION:
^ When pulling out harnesses, take care not to damage harnesses and connectors.
^ After temporarily securing, cover connectors with vinyl or similar material to protect against foreign material adhesion.
Vehicle Underbody
1. Remove exhaust front tube.
2. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft.
3. Remove propeller shaft.
CAUTION: Do not impact or damage propeller shaft tube.
4. Disengage A/T control rod at control device assembly side. Then, temporarily secure it on transmission, so that it does not sag (A/T models).
5. Disengage shift lever and clutch operating cylinder (M/T models).
6. Remove rear plate cover from oil pan (upper). Then, remove bolts fixing drive plate to torque converter (A/T models).
7. Remove bolts fixing transmission to lower rear side of oil pan (upper).
8. Remove front stabilizer.
9. Remove outer sockets from steering knuckle.
10. Remove lower ends of left and right shock absorber from transverse links.
Removal Work
1. Use a manual lift table caddy (commercial service tool) or equivalently rigid tool such as transmission jack. Securely support bottom of suspension member and transmission.
CAUTION: Put a piece of wood or something similar as the supporting surface, secure a completely stable condition.
2. Remove rear engine mounting member bolts.
3. Remove suspension member mounting bolts and nuts.
4. Carefully lower jack, or raise lift to remove engine, transmission and suspension member assembly. When performing work, observe the following caution.
CAUTION:
^ Confirm there is no interference with vehicle.
^ Make sure that all connection points have been disconnected.
^ Keep in mind the center of vehicle gravity changes. If necessary, use jack(s) to support vehicle at rear jacking point(s) to prevent it from falling it off the lift.
Separation Work
1. Install engine slingers into front of right bank cylinder head and rear of left bank cylinder head.
Slinger bolts: 24.5 - 31.4 Nm (2.5 - 3.2 kg-m, 18 - 23 ft. lbs.)
^ To protect rocker cover against damage caused by tilting of engine slinger, insert spacer between cylinder head and engine rear lower slinger, in direction shown in the figure.
NOTE: Spacer is a component part of engine rear upper slinger assembly.
2. Remove power steering oil pump from engine side.
3. Remove engine mounting insulators (RH and LH) under side nut.
4. Lift with hoist and separate engine and transmission assembly from suspension member.
CAUTION:
^ Before and during this lifting, always check if any harnesses are left connected.
^ Avoid damage to and oil/grease smearing or spills onto engine mounting insulator.
5. Remove alternator.
6. Remove starter motor.
7. Separate engine from transmission.
8. Remove engine mounting insulators (RH and LH) and brackets (RH and LH) from engine.
9. Remove engine mounting insulator (rear) and bracket (rear) from transmission.
INSTALLATION
Note the following, and install in the reverse order of removal.
^ For a location with a positioning pin, insert it securely into hole of mating part.
^ For a part with a specified installation orientation, refer to component figure in EM-130, "Components".
^ When installing engine mounting brackets (RH and LH) on cylinder block, tighten two upper bolts (shown as A in the figure) first. Then tighten two lower bolts (shown as B in the figure).
^ Tighten rear engine mounting member bolts in numerical order as shown in the figure.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
^ Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level.
^ Use procedure below to check for fuel leakage.
- Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
^ Run engine to check for unusual noise and vibration.
^ Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids including engine oil and engine coolant.
^ Bleed air from lines and hoses of applicable lines, such as in cooling system.
^ After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.
