Engine: Service and Repair

REMOVAL
1. CANADA: DISCONNECT RELAY BLOCK (FOR DAYTIME RUNNING LIGHT SYSTEM) FROM BATTERY HOLD-DOWN CLAMP
2. REMOVE BATTERY AND TRAY
3. REMOVE HOOD
4. REMOVE ENGINE UNDER COVER
5. REMOVE ENGINE FENDER APRON SEALS
6. DRAIN ENGINE COOLANT
7. DRAIN ENGINE OIL
8. DISCONNECT ACCELERATOR CABLE
9. REMOVE AIR CLEANER CAP ASSEMBLY AND AIR CLEANER CASE
10. REMOVE CRUISE CONTROL ACTUATOR
11. REMOVE RADIATOR





12. REMOVE FRONT EXHAUST PIPE
a. Remove the 2 bolts holding the support stay to the support bracket.
b. Remove the 2 bolts holding the support bracket to the front frame.
c. Remove the 2 bolts and 2 nuts holding the front exhaust pipe to the center exhaust pipe.
d. Remove the 4 nuts holding the front exhaust pipe to the exhaust manifolds.
e. Remove the front exhaust pipe and 3 gaskets.





13. DISCONNECT ENGINE WIRE FROM ENGINE COMPARTMENT RELAY BOX
a. Remove the bolt, and disconnect the relay box from the bracket on the body.
b. Remove the upper and lower covers.
c. Disconnect the 3 connectors and fusible link block from the relay box.
14. DISCONNECT CONNECTORS, CABLE, CLAMPS AND HOSES
^ Windshield wiper motor connector
^ Igniter connector on Left-Hand fender apron
^ Noise filter connector on Left-Hand fender apron
^ 2 ground strap connectors from Right-Hand fender apron
^ 2 ground strap connectors from Left-Hand fender apron
^ 2 engine room main wire connectors on Left-Hand fender apron
^ Ground cable from battery body bracket
^ Engine wire protector clamp from battery body bracket
^ Engine wire clamp from fuel filter
^ Engine wire clamp from bracket on Right-Hand fender apron
^ Brake booster vacuum hose from air intake chamber
^ Engine coolant reservoir hose from water outlet
^ Heater hose from intake manifold
^ Heater hose from water inlet housing
^ Fuel inlet hose from fuel filter

CAUTION: Perform disconnecting operation of the fuel tube connector (quick type) after observing the precautions.

^ EVAP hose from pipe on emission control valve set
^ EVAP hose from charcoal canister
^ 2 vacuum hoses from vacuum tank for Acoustic Control Induction System (ACIS)





15. DISCONNECT ENGINE WIRE FROM CABIN
a. Remove the under cover.
b. Disconnect these connectors:
^ 3 ECM connectors
^ 3 cowl wire connectors from connectors on bracket
c. Disconnect the grommet from the cowl panel, and pull out the engine wire.
16. REMOVE DRIVE SHAFTS





17. DISCONNECT A/C COMPRESSOR FROM ENGINE
a. Disconnect the A/C compressor connector.
b. Remove the drive belt.
c. Remove the 4 bolts, nut and drive belt adjusting bar bracket.
d. Disconnect the A/C compressor from the engine.
18. DISCONNECT TRANSAXLE CONTROL CABLE FROM TRANSAXLE





19. DISCONNECT PS PUMP FROM ENGINE
a. Remove the 2 nuts, and disconnect the PS pressure tube from the No.1 engine hanger.
b. Loosen the 2 bolts, and remove the drive belt.
c. Remove the 2 bolts, and disconnect the PS pump from the engine.





20. DISCONNECT TRANSAXLE FROM LEFT-HAND ENGINE MOUNTING INSULATOR
Remove the 4 bolts holding the transaxle to the mounting insulator.





21. DISCONNECT REAR ENGINE MOUNTING BRACKET FROM FRONT FRAME
a. Remove the 2 hole plugs.
b. Remove the 4 nuts holding the front frame to the mounting bracket.





22. REMOVE ENGINE MOUNTING ABSORBER
Remove the 4 bolts and mounting absorber.





23. DISCONNECT FRONT ENGINE MOUNTING INSULATOR FROM FRONT FRAME
Remove the 3 bolts holding the mounting insulator to the front frame.





24. ATTACH ENGINE SLING DEVICE TO ENGINE HANGERS
a. Install the No.2 engine hanger in the correct direction.
Part No.:
No.2 engine hanger 12282-20020
Bolt 91642-80825
Torque: 19.5 Nm (200 kgf.cm, 14 ft. lbs.)
b. Attach the engine sling device to the engine hangers.

CAUTION: Do not attempt to hang the engine by hooking the chain to any other part.





25. REMOVE RIGHT-HAND ENGINE MOUNTING STAY
Remove the 3 bolts, ground strap and Right-Hand engine mounting stay.





26. REMOVE ENGINE MOVING CONTROL ROD AND NO.2 RIGHT-HAND ENGINE MOUNTING BRACKET
Remove the 3 bolts, control rod and mounting bracket.





27. REMOVE ENGINE AND TRANSAXLE ASSEMBLY FROM VEHICLE
a. Lift the engine out of the vehicle slowly and carefully.

NOTICE: Be careful not to hit the PNP switch. Make sure the engine is clear of all wiring, hoses and cables.

b. Place the engine and transaxle assembly onto the stand.
28. REMOVE FRONT ENGINE MOUNTING INSULATOR FROM ENGINE
Remove the 4 bolts and mounting insulator.
29. REMOVE REAR ENGINE MOUNTING INSULATOR AND BRACKET ASSEMBLY FROM ENGINE
30. DISCONNECT THROTTLE CABLE FROM THROTTLE BODY
31. REMOVE STARTER
32. DISCONNECT ENGINE WIRE FROM TRANSAXLE
Disconnect these connectors and clamps:
^ VSS connector
^ PNP switch connector
^ Solenoid connector
^ Direct clutch speed sensor connector
^ 2 engine wire clamps from bracket
33. REMOVE TRANSAXLE





a. Remove the torque converter clutch mounting bolts.
1) Remove the 2 bolts and flywheel housing under cover.
2) Turn the crankshaft pulley bolt to gain access to each bolt.
3) Hold the crankshaft pulley bolt with a wrench, and remove the 6 bolts.
b. Remove the transaxle.





1) Remove the bolt, nut and Right-Hand exhaust manifold stay.
2) Remove the bolt, nut and Left-Hand exhaust manifold stay.





3) Remove the 8 bolts and ground strap.
4) Remove the transaxle together with the torque converter clutch from the engine.





34. REMOVE DRIVE PLATE
Remove the 8 bolts, rear plate, drive plate and front spacer.

INSTALLATION
1. INSTALL DRIVE PLATE





a. Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
b. Install the front spacer, drive plate and rear plate on the crankshaft.

Sequence:

c. Install and uniformly tighten the 8 bolts in several passes, in the sequence shown.
Torque: 83 Nm (850 kgf.cm, 61 ft. lbs.)
2. INSTALL TRANSAXLE TO ENGINE
a. Install the transaxle.
1) Attach the transaxle to the engine.





2) Install the ground strap and 8 bolts.
Torque:
14 mm head: 37.2 Nm (380 kgf.cm, 27 ft. lbs.)
17 mm head: 64 Nm (650 kgf.cm, 47 ft. lbs.)





3) California: Install the Right-Hand exhaust manifold stay.
Torque: 34 Nm (350 kgf.cm, 25 ft. lbs.)
4) Except California: Install the Right-Hand exhaust manifold stay with the bolt and nut.
Torque: 20 Nm (200 kgf.cm, 15 ft. lbs.)





5) Install the Left-Hand exhaust manifold stay with the bolt and nut.
Torque:
California: 34 Nm (350 kgf.cm, 25 ft. lbs.)
Except California: 20 Nm (200 kgf.cm, 15 ft. lbs.)
b. Install the torque converter clutch bolts.





1) Apply adhesive to 2 or 3 threads of the bolt.
Adhesive: Part No. 08833400070, THREE BOND 1324 or equivalent





2) Hold the crankshaft pulley bolt with a wrench, and install the 6 bolts evenly.
Torque: 41 Nm (420 kgf.cm, 30 ft. lbs.)

HINT: First install the dark green colored bolt, then install the other bolts.

3) Install the flywheel housing under cover with the 2 bolts.
Torque: 7.8 Nm (80 kgf.cm, 69 inch lbs.)
3. CONNECT ENGINE WIRE TO TRANSAXLE
Connect these connectors and clamps:
^ VSS connector
^ PNP switch connector
^ Solenoid connector
^ Direct clutch speed sensor connector
^ 2 wire clamps to bracket
4. INSTALL STARTER
5. CONNECT THROTTLE CABLE TO THROTTLE BODY
6. INSTALL REAR ENGINE MOUNTING INSULATOR
Install the mounting insulator with the 4 bolts.
Torque: 64 Nm (650 kgf.cm, 47 ft. lbs.)
7. INSTALL FRONT ENGINE MOUNTING INSULATOR
Install the mounting insulator with the 4 bolts.
Torque: 64 Nm (650 kgf.cm, 47 ft. lbs.)





8. 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 Left-Hand mounting.

NOTICE: Be careful not to hit the park/neutral position switch.

c. Keep the engine level, and align Right-Hand and Left-Hand mountings with the body bracket.





9. INSTALL NO.2 ENGINE MOUNTING BRACKET AND ENGINE MOVING CONTROL ROD
Install the mounting moving control rod and No.2 engine mounting bracket with the 3 bolts.
Torque: 64 Nm (650 kgf.cm, 47 ft. lbs.)





10. INSTALL RIGHT-HAND ENGINE MOUNTING STAY
Install the Right-Hand mounting stay with the 3 bolts.
Torque: 32 Nm (320 kgf.cm, 23 ft. lbs.)





11. CONNECT FRONT ENGINE MOUNTING INSULATOR
Connect the mounting insulator with the 3 bolts.
Torque:
Silver color bolt: 44 Nm (450 kgf.cm, 32 ft. lbs.)
Green color bolt: 66 Nm (670 kgf.cm, 49 ft. lbs.)





12. INSTALL ENGINE MOUNTING ABSORBER
Install the engine mounting absorber with the 4 bolts.
Torque: 48 Nm (490 kgf.cm, 35 ft. lbs.)





13. CONNECT REAR ENGINE MOUNTING INSULATOR
a. Connect the mounting insulator with the 4 nuts.
Torque: 66 Nm (670 kgf.cm, 48 ft. lbs.)
b. Install the 2 hole plugs.





14. CONNECT LEFT-HAND ENGINE MOUNTING INSULATOR
Connect the mounting insulator with the 4 bolts.
Torque: 64 Nm (650 kgf.cm, 47 ft. lbs.)
15. REMOVE ENGINE SLING DEVICE
16. CONNECT TRANSAXLE CONTROL CABLE TO TRANSAXLE





17. INSTALL PS PUMP
a. Install the PS pump with the 2 bolts.
Torque: 43 Nm (440 kgf.cm, 31 ft. lbs.)
b. Install the drive belt.
c. Connect the PS pressure tube with the 2 nuts.
d. Connect the 2 PS air hoses to the air intake chamber.





18. INSTALL A/C COMPRESSOR
a. Install the A/C compressor and drive belt adjusting bar bracket with the 4 bolts and nut.
Torque:
Bolt A: 25.5 Nm (260 kgf.cm, 19 ft. lbs.)
Bolt B: 18 Nm (185 kgf.cm, 13 ft. lbs.)
Nut C: 25.5 Nm (260 kgf.cm, 19 ft ft. lbs.)
b. Install the drive belt.
c. Connect the A/C compressor connector.
19. INSTALL DRIVE SHAFTS





20. CONNECT ENGINE WIRE TO CABIN
a. Push in the engine wire through the cowl panel. Install the grommet.
b. Connect these connectors.
^ 3 engine ECM connectors
^ 3 cowl wire connectors to connectors on bracket
c. Install the under cover.
21. CONNECT CONNECTORS, CABLE, CLAMPS AND HOSES
^ Windshield wiper motor connector
^ Igniter connector on Left-Hand fender apron
^ Noise filter connector on Left-Hand fender apron
^ 2 ground strap connectors to Right-Hand fender apron
^ 2 ground strap connectors to Left-Hand fender apron
^ 2 engine room main wire connectors on Left-Hand fender apron
^ Ground cable to battery body bracket
^ Engine wire protector clamp to battery body bracket
^ Engine wire clamp to fuel filter
^ Engine wire clamp to bracket on Right-Hand fender apron
^ Brake booster vacuum hose to air intake chamber
^ Engine coolant reservoir hose to water outlet
^ Heater hose to intake manifold
^ Heater hose to water inlet housing
^ Fuel inlet hose to fuel filter

CAUTION: Perform connecting operations of the fuel tube connector (quick type) after observing the precautions.

^ EVAP hose to pipe on emission control valve set
^ EVAP hose to charcoal canister
^ 2 vacuum hoses to vacuum tank for Acoustic Control Induction System (ACIS)
22. CONNECT ENGINE WIRE TO ENGINE COMPARTMENT RELAY BOX





23. INSTALL FRONT EXHAUST PIPE
a. Temporarily install 3 new gaskets and the front exhaust pipe with the 2 bolts and 6 nuts.
b. Tighten the 4 nuts holding the exhaust manifolds to the front exhaust pipe.
Torque: 62 Nm (630 kgf.cm, 46 ft. lbs.)
c. Tighten the 2 bolts and 2 nuts holding the front exhaust pipe to the center exhaust pipe.
Torque: 56 Nm (570 kgf.cm, 41 ft. lbs.)
d. Install the bracket with the 2 bolts.
Torque: 33 Nm (330 kgf.cm, 24 ft. lbs.)
e. Install the support stay with the 2 bolts.
Torque: 33 Nm (330 kgf.cm, 24 ft. lbs.)
24. INSTALL RADIATOR
25. INSTALL CRUISE CONTROL ACTUATOR
26. INSTALL AIR CLEANER CAP ASSEMBLY AND AIR CLEANER CASE
27. CONNECT ACCELERATOR CABLE
28. INSTALL ENGINE FENDER APRON SEALS
29. INSTALL BATTERY TRAY AND BATTERY
30. CANADA: INSTALL RELAY BLOCK (FOR DAYTIME RUNNING LIGHT SYSTEM) TO BATTERY HOLD-DOWN CLAMP
31. INSTALL HOOD
32. FILL ENGINE WITH OIL
33. FILL WITH ENGINE COOLANT
34. START ENGINE AND CHECK FOR LEAKS
35. INSTALL ENGINE UNDER COVER
36. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
37. RECHECK ENGINE COOLANT AND OIL LEVELS