Engine: Service and Repair

REMOVAL
1. FUEL OUTFLOW PREVENTION OPERATION
2. REMOVE FRONT TIRES
3. REMOVE CENTER ENGINE UNDERCOVER
4. DISCONNECT FENDER LINER LH AND RH
5. REMOVE LH AND RH FRONT FENDER APRON SEALS
6. DRAIN ENGINE COOLANT
7. A/T: DRAIN ATF
8. M/T: DRAIN TRANSMISSION OIL
9. DRAIN PS FLUID
10. REMOVE BATTERY AND TRAY
11. REMOVE AIR CLEANER CAP AND CASE
12. DISCONNECT ACCELERATOR CABLES
Disconnect the 2 accelerator cables from the throttle body.
13. DISCONNECT CRUISE CONTROL ACTUATOR
a. Disconnect the cruise control actuator connector.
b. Remove the 3 bolts and disconnect the actuator.
14. DISCONNECT RADIATOR HOSES
a. Disconnect the upper radiator hose from the radiator.
b. Disconnect the lower radiator hose from the water inlet.
15. A/T: DISCONNECT OIL COOLER HOSES
Loosen the 2 clips and disconnect the 2 oil cooler hoses.
16. DISCONNECT HEATER HOSES
a. Disconnect the heater hose from the intake manifold.
b. Disconnect the heater hose from the water inlet housing.
17. DISCONNECT SHIFT CONTROL CABLE(S)
a. M/T: Remove the 2 clamp, 2 pins and 2 washers and disconnect the 2 shift control cables
b. A/T: Remove the nut and clamp, and disconnect the cable from the transaxle.
18. M/T: REMOVE CLUTCH RELEASE CYLINDER AND PIPE
Remove the 4 bolts and clamp, disconnect the clutch release cylinder and pipe.





19. DISCONNECT ENGINE WIRE FROM CABIN
Disconnect the engine wire from the cabin.
1) Remove the No. 2 instrument panel.
2) Disconnect the 3 ECM connectors and 3 cowl wire connectors.
3) Disconnect the DLC1 from the bracket.
4) Disconnect the grommet from the cowl panel, and pull out the engine wire.
20. DISCONNECT ENGINE WIRES
a. Disconnect the ground wires.
1) RH side: Disconnect the 2 ground strap connectors.
2) LH side: Disconnect the 2 ground strap connectors.
3) Remove the bolt and disconnect the ground cable from the A/T.
b. Disconnect the engine wire from the J/B.
1) Disengage the 2 clamps and disconnect the engine wire cover from the LH fender apron.
2) Remove the J/B grommet.
3) Disconnect the No. 1 and No. 2 R/Bs from the J/B.
4) Disconnect the 4 connectors from the No. 1 and No. 2 R/Bs.
c. Disconnect the starter wire and connector.





21. DISCONNECT HOSES
a. Remove the fuel hose clamp and disconnect the fuel inlet hose from the fuel filter.
b. Disconnect the brake booster vacuum hose from the throttle body.
c. Disconnect the EVAP hose from the intake manifold.
d. Disconnect the 2 vacuum hose from the vacuum tank for the ACIS.





22. DISCONNECT PS HOSE FROM PS OIL RESERVOIR





23. DISCONNECT PS HOSE FROM PS RETURN TUBE
24. REMOVE DRIVE BELT AND GENERATOR
25. DISCONNECT A/C COMPRESSOR w/ PIPES FROM ENGINE
a. Disconnect the A/C compressor connector.





b. Remove the 2 bolts, nut and drive belt adjusting bar bracket.





c. Remove the 3 bolts.
d. Disconnect the A/C compressor and suspend it with ropes or similar objects.





26. REMOVE RH ENGINE MOUNTING STAY
Remove the 3 bolts and RH engine mounting stay.





27. M/T only:
REMOVE NO.2 RH ENGINE MOUNTING STAY
Remove the 2 bolts and RH engine mounting stay.





28. REMOVE ENGINE MOVING CONTROL ROD AND NO.2 RH ENGINE MOUNTING BRACKET
Remove the 3 bolts, control rod and mounting bracket.





29. DISCONNECT INTERMEDIATE SHAFT (Steering)
a. Place matchmarks on the intermediate shaft and control valve shaft.
b. Remove the bolt and disconnect the intermediate shaft.
30. DISCONNECT LH AND RH STABILIZER BAR LINKS
Remove the 2 nuts and LH and RH stabilizer bar links.
31. DISCONNECT LH AND RH DRIVE SHAFTS
Disconnect the drive shafts from the steering knuckle.
32. REMOVE FRONT EXHAUST PIPE





33. REMOVE ENGINE AND SUSPENSION MEMBER
a. Attach an engine jack to the front suspension member.
b. Remove the 2 bolts, 4 nuts, 4 long bolts and 4 suspension member lower braces.
c. Lower the engine and transaxle with the suspension member.

NOTICE: Be careful not to damage the engine wire, cables, hoses and pipes.

34. DISCONNECT PS PUMP AND PIPE
a. Disconnect the PS connector.
b. Remove the 2 bolts and disconnect the PS pump from the engine.
c. Remove the 2 nuts and disconnect the PS pipe from the engine.
35. SEPARATE ENGINE AND SUSPENSION MEMBER





a. Install the No.2 engine hanger with the 2 bolts.
Part No.: 12282-20020 for No. 2 engine hanger 91642-80825 for bolt
Torque: 19.5 Nm (200 kgf-cm, 14 ft. lbs.)
b. Attach the sling device to the engine hangers.
c. Using a hoist or a similar object, bring the engine and transaxle.





d. Remove the 2 hole plugs and nuts.





e. Remove the 2 bolts.





f. Remove the 3 bolts to the front frame.
g. Remove the 2 hole plugs.





h. Remove the 4 nuts to the front frame.
i. Separate the front suspension member with PS pump and gear box.
36. REMOVE FRONT ENGINE MOUNTING INSULATOR
Remove the 4 bolts and mounting insulator from the engine.
37. REMOVE REAR ENGINE MOUNTING INSULATOR
Remove the 4 bolts and mounting insulator from the engine.
38. REMOVE ENGINE MOUNTING ABSORBER
Remove the 2 bolts and absorber.
39. SEPARATE ENGINE AND TRANSAXLE for M/T for A/T

INSTALLATION
1. ASSEMBLE ENGINE AND TRANSAXLE for M/T for A/T
2. INSTALL FRONT SUSPENSION MEMBER TO ENGINE
a. Using a hoist or similar object, place the engine on the suspension member





b. Install the 4 nuts and 2 hole plugs.
Torque: 66 Nm (670 kgf-cm, 48 ft. lbs.)





c. Install the 3 front engine mounting insulator bolts.
Torque:
TMC made: 80 Nm (820 kgf-cm, 59 ft. lbs.)
TMMK made:
44 Nm (450 kgf-cm, 33 ft. lbs.) for silver bolt
66 Nm (670 kgf-cm, 48 ft. lbs.) for green bolt





d. Install the 2 engine mounting absorber bolts.
Torque: 48 Nm (490 kgf-cm, 35 ft. lbs.)





e. Install the 2 LH engine mounting insulator bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
3. CONNECT PS PUMP AND PIPE
a. Connect the PS pump with the 2 bolts.
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)
b. Connect the PS pipe with the 2 nuts.
c. Connect the PS connector.





4. INSTALL ENGINE AND SUSPENSION MEMBER
a. Remove the 2 bolts and No. 2 engine hanger.
b. Using an engine jack, lift the engine and suspension member.
c. Attach the suspension member to the vehicle.
d. Install the 2 bolts, 4 nuts, 4 long bolts, front LH and RH lower braces and rear LH and RH lower braces.
Torque:
181 Nm (1,850 kgf-cm, 134 ft. lbs.) for bolt A
32 Nm (330 kgf-cm, 24 ft. lbs.) for bolt B
36 Nm (370 kgf-cm, 27 ft. lbs.) for nut C
e. Remove the engine jack.
5. INSTALL FRONT EXHAUST PIPE
6. CONNECT LH AND RH DRIVE SHAFTS
7. CONNECT LH AND RH STABILIZER BAR LINKS
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)





8. CONNECT INTERMEDIATE SHAFT ASSEMBLY
Connect the intermediate shaft assembly and install the bolt as shown in the illustration.
Torque: 35 Nm (360 kgf-cm, 26 ft. lbs.)





9. INSTALL NO. 2 RH ENGINE MOUNTING BRACKET
Install the control rod and mounting bracket with the 4 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)





10. INSTALL RH ENGINE MOUNTING STAY
Install the RH engine mounting stay and 3 bolts.
Torque: 32 Nm (320 kgf-cm, 23 ft. lbs.)





11. M/T only:
INSTALL NO.2 RH ENGINE MOUNTING STAY
Install the RH engine mounting stay and 2 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
12. INSTALL A/C COMPRESSOR





a. Install the 3 bolts.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)





b. Install the 2 bolts, nut and drive belt adjusting bar bracket.
Torque:
25 Nm (250 kgf-cm, 18 ft. lbs.) for bolt A
18 Nm (185 kgf-cm, 13 ft. lbs.) for bolt B
25 Nm (250 kg. -cm, IS ft. lbs.) for nut C
c. Connect the A/C compressor connector.
13. INSTALL GENERATOR AND DRIVE BELT





14. CONNECT PS HOSE TO PS RETURN TUBE





15. CONNECT PS HOSE TO PS OIL RESERVOIR





16. CONNECT HOSES
a. Connect the fuel inlet hose to the fuel filter and install the fuel hose clamp.
b. Connect the brake booster vacuum hose to the throttle body.
c. Connect the EVAP hose to the intake manifold.
d. Connect the 2 vacuum hose to the vacuum tank for the ACIS.
17. CONNECT ENGINE WIRE
a. Connect the engine wire from the J/B.
1) Connect the 4 connectors to the No. 1 and No. 2 R/Bs.
2) Connect the No. 1 and No. 2 R/Bs to the J/B.
3) Install the J/B grommet.
4) Engage the 2 clamps and connect the engine wire cover to the LH fender apron.
b. Connect the ground wires.
1) Connect the ground cable and install the bolt to the A/T.
2) RH side: Connect the 2 ground strap connectors.
3) LH side: Connect the 2 ground strap connectors.
c. Connect the starter wire and connector.





18. CONNECT ENGINE WIRE TO CABIN
a. Connect the engine wire to the cabin.
1) Install the engine wire, and connect the grommet to the cowl panel.
2) Connect the DLC1 to the bracket.
3) Connect the igniter connector.
4) Connect the noise filter connector.
5) Connect the 3 ECM connectors and 3 cowl wire connectors.
6) Install the No. 2 instrument panel.
19. M/T: CONNECT CLUTCH RELEASE CYLINDER AND PIPE
Connect the clutch release cylinder and pipe with the clamp and 4 bolts.
20. CONNECT SHIFT CONTROL CABLE(S)
a. M/T: Connect the 2 shift control cables with the 2 clamps, 2 washers and 2 pins.
b. A/T: Connect the shift control cable with the clamp and nut.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
21. ADJUST SHIFT LEVER POSITION
22. CONNECT HEATER HOSES
a. Connect the heater hose to water inlet housing.
b. Connect the heater hose to intake manifold.
23. A/T: CONNECT OIL COOLER HOSES
Connect the 2 clips and 2 oil cooler hoses.
24. CONNECT RADIATOR HOSES
a. Connect the upper radiator hose to the radiator.
b. Connect the lower radiator hose to the water inlet.
25. INSTALL CRUISE CONTROL ACTUATOR
a. Install the actuator with the 3 bolts.
Torque: 13 Nm (130 kgf-cm, 9 inch lbs.)
b. Connect the cruise control actuator connector.
26. CONNECT ACCELERATOR CABLES
Connect the 2 accelerator cables to the throttle body.





27. ADJUST ACCELERATOR CABLE
a. Check that the accelerator pedal is fully released.
b. Check that the inner cable is not slack.
c. Measure the distance between the outer cable end and stopper on the cable.
Standard distance: 0 - 1 mm (0 - 0.04 inch)
If the distance is not standard, adjust the cable by the adjusting nuts.
28. INSTALL AIR CLEANER CAP AND CASE
29. INSTALL BATTERY AND TRAY
30. FILL ENGINE COOLANT
31. FILL PS FLUID AND BLEED AIR
32. M/T: FILL TRANSMISSION OIL
33. A/T: FILL ATF
34. INSTALL LH AND RH FRONT FENDER APRON SEALS
35. INSTALL LH AND RH FENDER LINERS
36. INSTALL CENTER ENGINE UNDER COVER
37. INSTALL FRONT TIRES
38. ADJUST FRONT WHEEL ALIGNMENT
39. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
40. RECHECK ENGINE COOLANT, ATF AND PS FLUID LEVEL