Engine: Service and Repair

REMOVAL
1. Remove battery.
2. Remove hood.
3. Remove engine under covers.
4. Drain engine coolant.
5. Drain transaxle oil (fluid).
6. Disconnect VSV for EVAP bracket.
7. Remove air cleaner assembly with air intake connector.
8. Remove radiator.
9. Disconnect accelerator cable.

10. Disconnect fuel hose.
Remove the union bolt and gaskets, and disconnect the fuel inlet hose.

CAUTION: Catch leaking fuel in a container.

11. Disconnect hoses.

Disconnect these hoses:
^ Brake booster vacuum hose.
^ MAP sensor hose.
^ Heater hoses.
12. Disconnect speedometer cable from transaxle.

13. w/ PS: Disconnect idle-up air hoses from air control valve.
14. Disconnect engine wire harness.
Disconnect these connectors and wires:
^ Oxygen sensor connector.
^ Oil pressure switch connector.
^ Engine coolant temperature sender gauge connector.
^ Engine coolant temperature sensor connector.
^ Camshaft position sensor connector.
^ Fan engine coolant temperature switch connector.
^ A/T only: Lock-up solenoid connector.
^ A/T only: Park/Neutral position switch connector.
^ M/T only: Backup light switch connector.
^ A/T only: No. 2 vehicle speed sensor connector.
^ Ground strap.
^ Throttle position sensor connector.
^ IAC valve connector.
^ Injector connectors.
^ Crankshaft position sensor connector.
^ Knock sensor connector.
^ Starter connector and wire.
^ Generator connector and wire.

15. M/T only: Remove clutch release cylinder without disconnecting tube.
(a) Remove the 3 bolts, release cylinder and tube from the transaxle.
Disconnect the ground strap.
16. Disconnect control cable(s) from transaxle.

M/T
(a) Remove the clip and plate washer.
(b) Remove the retainer from the cable.

A/T
(a) Remove the clip and plate washer.
(b) Remove the 2 bolts from the LH engine mounting bracket.

17. w/ PS: Remove PS pump without disconnecting hoses.
(a) Loosen the 2 bolts, and remove the PS drive belt.
(b) Remove the 2 bolts, and disconnect the PS pump from the engine.

NOTE: Put aside the PS pump, and suspend it.

18. w/ A/C: Remove A/C compressor.
(a) Disconnect the compressor connector.

(b) Remove the 4 compressor mounting bolts.

NOTE: Put aside the compressor, and suspend it.

19. Remove front exhaust pipe.
(a) Disconnect the heated oxygen sensor.
(b) Remove the 2 bolts, compression springs and disconnect the exhaust pipe.
(c) Remove the bolts and rear clamp.
(d) Disconnect the 2 rings and remove the front exhaust pipe.
20. Remove drive shafts.
21. Remove engine with transaxle from vehicle.

(a) Install the No. 1 engine hanger in the correct direction.
Part No.: No. 1 engine hanger 12281 - 11031
Bolt 91642 - 80825
(b) Attach the engine sling device to the engine hangers.

(e) Remove the bolt and disconnect the ground strap.
(f) Remove the through bolt, 2 bolts, nut and RH engine mounting insulator.

(g) Remove the bolt and disconnect the ground strap.
(h) Remove the 5 bolts and LH engine mounting bracket.

(i) Lift the engine out of the vehicle slowly and carefully.

NOTE: Clear the battery carrier support while lowering the transaxle.

(j) Place the engine with the transaxle onto the stand.

22. w/PS: Remove PS pump adjusting strut.
Remove the 2 bolts and PS pump adjusting strut.

23. w/A/C: Remove A/C compressor mounting bracket.
Remove the 4 bolts and compressor mounting bracket.

24. A/T only: Remove torque converter clutch mounting bolts.
(a) Remove the engine rear end plate hole cover.
(b) Turn the crankshaft to gain access to each bolt.
(c) Hold the crankshaft pulley bolt with a wrench.
(d) Remove the 6 bolts.
25. Remove starter.
26. Separate engine and transaxle.

INSTALLATION
1. Assemble engine and transaxle.
2. Install starter.
3. A/T only: Install torque converter clutch mounting bolts.

(a) First, install the gray bolt and then 5 bolts.
(b) Tighten the bolts evenly.
Torque: 27 Nm (280 kg.cm, 20 ft. lbs.)
(c) Install the engine rear end plate hole cover.
4. w/A/C: Install A/C compressor mounting bracket.

Install the compressor mounting bracket with the 4 bolts.
Torque: 27 Nm (280 kg.cm, 20 ft. lbs.)
5. w/PS: Install PS pump adjusting strut.

Install the PS pump adjusting strut with the 2 bolts.
Torque: 21 Nm (210 kg.cm, 15 ft. lbs.)
6. Install engine and transaxle assembly in vehicle.
(a) Attach the engine sling device to the engine hangers.

(b) Lower the engine into the engine compartment.
Tilt the transaxle downward, lower the engine and clear the LH engine mounting.

CAUTION: Be careful not to hit the PS gear housing, park/ neutral position switch and throttle position switch.

(d) Attach the RH engine mounting insulator to the mounting bracket and body, and temporarily install the through bolt, 2 bolts and nut.

(e) Install the LH engine mounting bracket to the transaxle and mounting insulator with the 5 bolts. Torque the bolts.
Torque:
Bracket to transaxle (bolt head: NT): 65 Nm (650 kg.cm, 47 ft. lbs.)
Bracket to insulator (bolt head: NT): 49 Nm (490 kg.cm, 35 ft. lbs.)
(f) Connect the ground strap with the bolt.
Torque: 49 Nm (490 kg.cm, 35 ft. lbs.)

(g) Install and torque the rear engine mounting insulator through bolt.
Torque: 65 Nm (650 kg.cm, 47 ft. lbs.)
(h) Remove the engine sling device from the engine.

(i) Torque the 2 bolts, nut and through bolt of the RH mounting insulator.
Torque:
Bolt and nut: 64 Nm (650 kg.cm, 47 ft. lbs.)
Through bolt: 73 Nm (740 kg.cm, 54 ft. lbs.)
(j) Connect the ground strap with the bolt.
(k) Install charcoal canister.
7. Install drive shafts.

8. Install front exhaust pipe.
(a) Connect the 2 rings to the front exhaust pipe.
(b) Place a new gasket on the exhaust pipe.
(c) Connect the exhaust pipe to the exhaust manifold with 2 compression springs and 2 bolts.
Torque: 62 Nm (630 kg.cm, 46 ft. lbs.)
(d) Install the exhaust pipe to the tail pipe with the clamp.
Torque: 19 Nm (190 kg.cm, 14 ft. lbs.)
(e) Install the heated oxygen sensor.
Torque: 44 Nm (450 kg.cm, 33 ft. lbs.)

NOTE:
^ Before installing the heated oxygen sensor, twist the sensor wire counterclockwise 3 and 1/2 turns.
^ After installing the heated oxygen sensor, check that the sensor wire is not twisted. If it is twisted, remove the heated oxygen sensor and reinstall it.

9. w/ A/C: Install A/C compressor.

(a) Install the A/C compressor to the bracket with the 4 bolts.
Torque: 25 Nm (250 kg.cm, 18 ft. lbs.)
(b) Connect A/C compressor connector.
1O. w/ PS: Install PS pump.

(a) Install the PS pump and drive belt with the 2 bolts.
(b) Adjust the drive belt tension.
11. Connect control cable(s) to transaxle.

M/T:
(a) Install the retainer to the cable.
(b) Connect the linkage with the plate washer and clip.

A/T:
(a) Install the support bracket to the LH engine mounting bracket with the 2 bolts.
(b) Connect the linkage with the plate washer and clip.

12. M/T only: Install clutch release cylinder.
Install the release cylinder, tube and ground strap with the 3 bolts.
Torque: 12 Nm (120 kg.cm, 9 ft. lbs.)
13. Connect engine wire harness.
Connect these connectors and wires:
^ Oxygen sensor connector.
^ Oil pressure switch connector.
^ Engine coolant temperature sender gauge connector.
^ Engine coolant temperature sensor connector.
^ Camshaft position sensor connector.
^ Fan engine coolant temperature switch connector.
^ A/T only: Lock-up solenoid connector.
^ A/T only: Park/Neutral position switch connector.
^ M/T only: Backup light switch connector.
^ A/T only: No. 2 vehicle speed sensor connector.
^ Ground strap:
^ Throttle position sensor connector.
^ IAC valve connector.
^ Injector connectors.
^ Crankshaft position sensor connector.
^ Knock sensor connector.
^ Starter connector and wire.
^ Generator connector and wire.

14. w/ PS: Connect idle-up air hoses to air control valve.
15. Connect speedometer cable.

16. Connect hoses.
Connect these hoses:
(1) Brake booster vacuum hose.
(2) MAP sensor hose.
(3) Heater hoses.

17. Connect fuel hose.
Connect the fuel inlet hose with the union bolt and 2 new gaskets.
Torque: 29.5 Nm (300 kg.cm, 22 ft. lbs)
18. Connect accelerator cable, and adjust it.
19. Install radiator.
20. Install air cleaner assembly with air intake connector.
21. Fill with transaxle oil (fluid).
22. Fill with engine coolant.
23. Install engine under covers.
24. Install hood.
25. Start engine and check for leaks.
26. Perform engine adjustment.
27. Perform road test.
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
28. Recheck engine coolant and engine oil levels.