Engine: Service and Repair
Part 1 Of 5:
Part 2 Of 5:
Part 3 Of 5:
Part 4 Of 5:
Part 5 Of 5:
REMOVAL
1. REMOVE CENTER ENGINE UNDERCOVER
2. DISCONNECT FENDER LINER LH AND RH
3. REMOVE LH AND RH FRONT FENDER APRON SEALS
4. DRAIN ENGINE COOLANT
5. DRAIN ENGINE OIL
6. REMOVE DRAIN PLUG AND DRAIN ATF
7. DRAIN PS FLUID
8. REMOVE BATTERY AND TRAY
9. REMOVE V-BANK COVER
Remove the 3 nuts, fastener and V-bank cover.
10. REMOVE AIR CLEANER CAP
11. REMOVE AIR CLEANER CASE
a. Remove the air filter.
b. Remove the 3 bolts and air cleaner case.
12. DISCONNECT ACCELERATOR AND THROTTLE CABLES
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. DISCONNECT A/T OIL COOLER HOSES
a. Disconnect the oil cooler hose from the oil cooler pipe.
b. Remove the bolt and disconnect the oil cooler pipe from the frame.
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 A/T SHIFT CONTROL CABLE
Remove the nut and clamp, and disconnect the cable from the transaxle.
18. 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.
19. DISCONNECT ENGINE WIRE
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.
20. 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 assembly from the pipe on the emission control valve set.
d. Disconnect the 2 vacuum hoses from the vacuum tank for the ACIS.
21. DISCONNECT PS HOSE FROM PS OIL RESERVOIR
22. DISCONNECT PS HOSE FROM PS RETURN TUBE
23. DISCONNECT VSV FROM FRONT ENGINE MOUNTING INSULATOR
24. REMOVE GENERATOR
25. DISCONNECT A/C COMPRESSOR WITH 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 ENGINE MOVING CONTROL ROD AND NO.2 RH ENGINE MOUNTING BRACKET
Remove the 4 bolts, control rod and mounting bracket.
27. DISCONNECT INTERMEDIATE SHAFT
a. Place matchmarks on the intermediate shaft and control valve shaft.
b. Remove the bolt and disconnect the intermediate shaft.
28. DISCONNECT LH AND RH STABILIZER BAR LINKS
Remove the 2 nuts, and LH and RH stabilizer bar links.
29. DISCONNECT LH AND RH DRIVE SHAFTS
a. Remove the drive shaft lock nut.
1. Remove the cotter pin and lock cap.
2. With applying the brakes, remove the nut.
b. w/ ABS: Remove the ABS speed sensor and wire harness clamp.
c. Disconnect the tie rod end from the steering knuckle.
1. Remove the cotter pin and nut.
2. Using SST disconnect the tie rod end from the steering knuckle.
SST 09610-20012
d. Disconnect the lower ball joint from the lower arm.
Remove the 2 nuts and bolt.
e. Disconnect the drive shaft from the axle hub.
1. Using a plastic hammer, disconnect the drive shaft from the axle hub.
NOTICE: Cover the drive shaft boot with cloth to protect it from damage.
2. Push the front axle hub toward the outside of the vehicle, and separate the drive shaft from the axle hub.
30. REMOVE FRONT EXHAUST PIPE
a. Remove the 2 bolts holding the support stay to the support bracket.
b. Remove the 2 bolts and 2 compression springs holding the front exhaust pipe to the center exhaust pipe.
c. Remove the 4 nuts holding the front exhaust pipe to the exhaust manifolds.
d. Remove the front exhaust pipe and 3 gaskets.
31. REMOVE ENGINE AND TRANSAXLE W/ FRONT SUSPENSION MEMBER ASSEMBLY
a. Attach an engine jack to the front suspension member.
b. Remove the 2 bolts, 4 nuts, 4 long bolts and 4 suspension member brackets.
c. Lower the engine and transaxle with the suspension member,
NOTICE: Be careful not to damage the engine wire, cables, hoses and pipes.
32. REMOVE PS VANE PUMP ASSEMBLY
33. 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 90080-11331
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.
CAUTION: Do not attempt to hang the engine by hooking the chain to any other part.
34. SEPARATE FRONT SUSPENSION MEMBER ASSEMBLY FROM ENGINE AND TRANSAXLE
a. Remove the 4 bolts holding the transaxle to the LH mounting insulator.
b. Remove the 4 bolts and engine mounting absorber.
c. Remove the 3 bolts holding the front suspension member assembly to the front engine mounting insulator.
d. Remove the 2 hole plugs.
e. Remove the 4 nuts holding the front suspension member assembly and rear engine mounting bracket.
f. Separate the front suspension member assembly from the engine and transaxle.
35. REMOVE FRONT ENGINE MOUNTING INSULATOR FROM ENGINE
Remove the 4 bolts and mounting insulator.
36. REMOVE REAR ENGINE MOUNTING INSULATOR AND BRACKET ASSEMBLY FROM ENGINE
Remove the 4 bolts, the mounting insulator and bracket assembly.
37. SEPARATE ENGINE AND TRANSAXLE
INSPECTION
1. INSPECT FRONT ENGINE MOUNTING INSULATOR
a. Using a MITYVAC (Hand-Held Vacuum Pump), apply vacuum of 80 kPa (600 mmHg, 25 inch Hg) and allow it to stand for 1 minute.
b. Check that there is no change in the needle movement.
c. Check that there is no fluid leakage caused by a break of a lower diaphragm.
If the operation is not as specified, replace the insulator.
2. INSPECT VSV FOR ACTIVE CONTROL ENGINE MOUNT
a. Inspect the VSV for open circuit.
Using an ohmmeter, check that there is continuity between the terminals.
Resistance: 19 - 21 Ohms at 20°C (68°F)
If there is no continuity, replace the VSV.
b. Inspect the VSV for ground.
Using an ohmmeter, check that there is no continuity between each terminal and the body.
If there is continuity, replace the VSV
c. Inspect the VSV operation.
1. Check that air flows from port G to port E and port H.
2. Apply battery positive voltage across the terminals.
3. Check that air flows from port F to port E and port H.
If operation is not as specified, replace the VSV.
3. INSPECT VACUUM TANK
INSTALLATION
1. ASSEMBLE ENGINE AND TRANSAXLE
2. INSTALL REAR ENGINE MOUNTING INSULATOR
Install the mounting insulator with the 4 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
3. INSTALL FRONT ENGINE MOUNTING INSULATOR
Install the mounting insulator with the 4 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
4. INSTALL PS VALVE PUMP ASSEMBLY
5. INSTALL FRONT SUSPENSION MEMBER ASSEMBLY TO ENGINE AND TRANSAXLE
a. Attach the suspension member assembly to the engine and transaxle.
b. Install the 4 nuts holding the front suspension member assembly and rear engine mounting bracket.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
c. Install the 2 hole plugs.
d. Install the 3 bolts holding the front suspension member assembly to the front engine mounting member.
Torque: 66 Nm (670 kgf-cm, 48 ft. lbs.) for green color bolt 44 Nm (450 kgf-cm, 32 ft. lbs.) for silver color bolt
e. Install the engine mounting absorber with the 4 bolts.
Torque: 48 Nm (490 kgf-cm, 35 ft. lbs.)
f. Install the 4 bolts holding the transaxle to the LH mounting insulator.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
g. Remove the sling device.
h. Remove the 2 bolts and No. 2 engine hanger.
6. INSTALL ENGINE AND TRANSAXLE w/ FRONT SUSPENSION MEMBER ASSEMBLY
a. Using an engine jack, support the engine and transaxle with suspension member assembly.
b. Attach the engine and transaxle with suspension member assembly to the vehicle.
c. Install the 2 bolts, 4 nuts, 4 long bolts, LH and RH front suspension members and LH and RH rear suspension members.
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
d. Remove the engine jack.
7. INSTALL FRONT EXHAUST PIPE
a. Temporarily install 3 new gaskets and the front exhaust pipe with the 2 bolts, 2 compression springs and 4 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 compression springs holding the front exhaust pipe to the center exhaust pipe.
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)
d. Install the support stay with the 2 bolts.
Torque: 33 Nm (330 kgf-cm, 24 ft. lbs.)
8. CONNECT LH AND RH DRIVE SHAFTS
a. Connect the drive shaft to the axle hub.
Lowering the lower arm, connect the drive shaft to the axle hub.
b. Connect the lower ball joint to the lower arm. Install the 2 nuts and bolt.
c. Connect the tie rod end to the steering knuckle.
Torque: 127 Nm (1,300 kgf-cm, 94 ft. lbs.)
1. Connect the tie rod end and install the nut.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
2. Install a new cotter pin.
d. w/ ABS: Install the ABS speed sensor and wire harness clamp.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)
e. Install the drive shaft lock nut.
1. Install the nut.
Torque: 294 Nm (3,000 kgf-cm, 217 ft. lbs.)
2. Install a new cotter pin and lock cap.
9. CONNECT LH AND RH STABILIZER BAR LINKS
Connect the LH and RH stabilizer links, install the 2 nuts.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
HINT: If the ball joint turns together with the nut, use a 5 mm hexagon wrench to hold the stud.
10. 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.)
11. INSTALL NO. 2 RH ENGINE MOUNTING BRACKET AND ENGINE MOVING CONTROL ROD
a. Temporarily install the No. 2 RH engine mounting bracket and engine moving control rod with the 3 bolts.
b. Tighten the bolt (A).
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
c. Tighten the other 3 bolts (B, C and D).
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.) for bolts B and C 32 Nm (320 kgf-cm, 23 ft. lbs.) for bolt F
12. INSTALL A/C COMPRESSOR
a. Install the A/C compressor with 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 kgf-cm, 18 ft. lbs.) for nut C
c. Connect the A/C compressor connector,
13. INSTALL GENERATOR
14. CONNECT VSV TO FRONT ENGINE MOUNTING INSULATOR
15. CONNECT PS HOSE TO PS RETURN TUBE
16. CONNECT PS HOSE TO PS OIL RESERVOIR
17. 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 assembly to the pipe on the emission control valve set.
d. Connect the 2 vacuum hoses to the vacuum tank for the ACIS.
18. 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.
19. CONNECT ENGINE WIRE TO CABIN
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 ignitor 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.
20. CONNECT A/T SHIFT CONTROL CABLE TO TRANSAXLE
21. CONNECT HEATER HOSES
a. Connect the heater hose to water inlet housing.
b. Connect the heater hose to intake manifold.
22. CONNECT ATF OIL COOLER HOSES
a. Install the oil cooler pipe to the frame with the bolt.
b. Connect the oil cooler hose to the oil cooler pipe.
23. CONNECT RADIATOR HOSES
a. Connect the upper radiator hose to the radiator.
b. Connect the lower radiator hose to the water inlet.
24. 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.
25. CONNECT ACCELERATOR AND THROTTLE CABLES
26. INSTALL AIR CLEANER CASE
a. Install the air cleaner case and 3 bolts.
b. Install the air filter.
27. INSTALL AIR CLEANER CAP
28. INSTALL BATTERY AND TRAY
29. INSTALL V-BANK COVER
Install the V-bank cover, 3 nuts and fastener.
30. FILL ENGINE COOLANT
31. FILL PS FLUID AND BLEED AIR
32. FILL TRANSAXLE WITH ATF
33. INSTALL LH AND RH FRONT FENDER APRON SEALS
34. INSTALL LH AND RH FENDER LINERS
35. INSTALL CENTER ENGINE UNDER COVER
36. FILL ENGINE WITH OIL
37. FILL WITH ENGINE COOLANT
38. START ENGINE AND CHECK FOR LEAKS
39. CHECK AND ADJUST FRONT WHEEL ALIGNMENT
40. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
41. RECHECK ENGINE COOLANT AND OIL LEVELS