Engine: Service and Repair
ENGINE ASSEMBLYRemoval and Installation
EM-177 Component:
WARNING:
^ Place chocks at the front and back of the rear wheels.
^ For engines not equipped with slingers, attach proper slingers and bolts as described in the parts catalog.
CAUTION:
^ Do not start working until the exhaust system and coolant are cool.
^ If items or work required are not covered by the engine main body section, follow the applicable procedures.
^ Use the correct supporting points for lifting and jacking. Refer to GI-38. Garage Jack and Safety Stand
^ In removing the drive shaft, be careful not to damage the grease seals on the transaxle.
^ Before separating the engine and transaxle, remove the crankshaft position sensor (POS) from the assembly.
^ Be sure not to damage the edge of the crankshaft position sensor (POS) or the ring gear teeth.
REMOVAL
1. Release fuel pressure.
2. Disconnect the fuel rail at the fuel hose quick connector (engine side).
3. Drain the engine oil.
4. Drain the engine coolant.
5. Remove the engine hood assembly.
6. Remove cowl extension.
7. Remove the battery, battery hold downs, and battery tray.
8. Disconnect the MAF sensor electrical connector.
9. Remove the air duct and air cleaner case assembly.
10. Disconnect the heater hoses.
11. Remove engine cover using power tool.
12. Remove the engine coolant reservoir tank, radiator and radiator fan assembly.
13. Disconnect and set aside the IPDM/ER and remove the IPDM/ER bracket
14. Remove the generator.
15. Remove the engine under covers and splash shield using power tool.
16. Dismount the A/C compressor with piping connected and secure with wire to the radiator support.
17. Disconnect the engine wiring harness retainers and ground strap.
18. Remove clutch operating cylinder from transaxle, and move it aside (M/T models).
19. Disconnect the transaxle shift controls.
20. Remove front exhaust tube.
21. Remove the left and right drive shafts.
23. Install engine slingers into front left cylinder head and rear right cylinder head.
^ Use generator bracket bolt holes for the front slinger.
^ Use the proper slingers and bolts as described in the Parts Catalog.
Slinger bolts - front (B): 48 Nm (4.9 kg-m, 35 ft-lb)
Slinger bolts - rear (A): 28 Nm (2.8 kg-m, 21 ft-lb)
24. Support engine and transaxle assembly with engine lifting equipment from the top with the vehicle raised on a hoist.
25. Remove RH engine mounting insulator and bracket.
26. Remove LH transaxle mounting insulator through-bolts.
27. Lower the engine and transaxle assembly from the engine compartment using Tool.
CAUTION:
^ Before and during this procedure, always check if any harnesses are left connected.
^ Avoid any damage to, or any oil/grease smearing or spills onto the engine mounting insulators.
Tool number: - (J-47242)
28. Remove the starter motor.
29. Separate engine and transaxle.
INSTALLATION
Combine engine and transaxle assembly.
Installation is in the reverse order of removal.
^ Do not allow oil to get on mounting insulators. Be careful not to damage mounting insulators.
^ If parts have a direction mark (arrow) this indicates front of the vehicle, and the parts must be installed according to the identification mark.
INSPECTION AFTER INSTALLATION
^ 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 gas, or any oils/fluids including engine oil and engine coolant.
^ Bleed air from passages in lines and hoses, such as in cooling system.
^ After cooling down engine, again check oils/fluids including engine oil and engine coolant. Refill to specified level, if necessary.
^ Summary of the inspection items:
