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 BATTERY AND TRAY
2. REMOVE HOOD
3. REMOVE OUTER FRONT COWL TOP PANEL
4. REMOVE ENGINE UNDER COVERS
5. DRAIN ENGINE COOLANT
6. DRAIN ENGINE OIL
7. DRAIN TRANSAXLE OIL
8. DISCONNECT ACCELERATOR CABLE
9. REMOVE AIR CLEANER CAP
a) Disconnect the MAF sensor connector.
b) Disconnect the PCV hose from the cylinder head.
c) Disconnect the 2 hose from the VSV for EVAP
d) Disconnect the 2 clamps, and disconnect the air cleaner cap from the air cleaner case.
e) Loosen the hose clamp, and disconnect the air cleaner hose from the throttle body.
f) Remove the air cleaner cap and air cleaner hose assembly.
10. REMOVE AIR CLEANER CASE
a) Remove the air filter.
b) Remove the 4 bolts and air cleaner case and air cleaner inlet assembly.
11. DISCONNECT TUBE, HOSES AND CONNECTORS
a) Remove the fuel pipe clamp.
b) Disconnect the fuel tube from fuel pipe on vehicle side.
c) Disconnect the heater hose from water bypass pipe.
d) Disconnect the brake booster vacuum hose from pipe.
e) Disconnect the heater hose from water hose union on cylinder head.
12. REMOVE DRIVE BELT AND GENERATOR
13. REMOVE RADIATOR ASSEMBLY
14. w/A/C:
DISCONNECT A/C COMPRESSOR FROM ENGINE
a) Disconnect the A/C compressor connector.
b) Remove the 4 bolts, and disconnect the A/C compressor from the engine.
HINT: Suspend the A/C compressor securely.
15. M/T:
DISCONNECT CLUTCH RELEASE CYLINDER FROM TRANSAXLE
a) Remove the bolt, and disconnect the bracket from the transaxle.
b) Remove the 2 bolts, and disconnect the release cylinder from the transaxle.
16. DISCONNECT TRANSAXLE CONTROL CABLE(S) FROM TRANSAXLE
17. DISCONNECT ENGINE WIRE FROM ENGINE COMPARTMENT
a) Disconnect the connector from the relay box.
b) Disconnect the cable clamp from the relay box.
c) Disconnect the connector from the fusible link.
d) Disconnect the positive cable from the positive terminal.
18. DISCONNECT ENGINE WIRE FROM CABIN
a) Remove the lower panel.
b) Disconnect the 4 ECM connectors.
c) Disconnect the 2 cowl wire connectors from connectors on bracket.
d) Pull out the engine wire from the cabin.
19. DISCONNECT PS PUMP FROM ENGINE
20. REMOVE CENTER EXHAUST PIPE
a) Disconnect the rear heated oxygen sensor.
b) Disconnect the connector for front heated oxygen sensor.
c) Remove the 2 bolts and floor brace.
d) Remove the 3 bolts, 2 springs and pipe clamp.
e) Disconnect the 2 O-ring, and remove the center exhaust pipe and 2 gaskets.
21. REMOVE DRIVE SHAFTS
22. REMOVE SUSPENSION MEMBER
23. REMOVE REAR ENGINE MOUNTING
a) Remove the through bolt, lock nut and rear engine mounting insulator.
b) Remove the 2 bolts, nut and rear engine mounting bracket.
24. ATTACH ENGINE SLING DEVICE TO ENGINE HANGERS
a) Remove the bolt, and disconnect the condenser.
b) Install the 2 engine hangers in the correct direction.
Engine hanger part No.: 12281-21010
Bolt part No.:
91512-B1016 2 pieces
Torque: 38 Nm (388 kgf-cm, 28 ft. lbs.)
c) 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 ENGINE AND TRANSAXLE ASSEMBLY FROM VEHICLE
a) Remove the 2 bolts, and disconnect the LH engine mounting.
b) Remove the 2 bolts and nut, and disconnect the RH engine mounting.
c) Remove the bolt holding the liquid tube to the RH engine mounting insulator.
d) Remove the 3 bolts and RH engine mounting insulator.
e) Lift the engine out of the vehicle slowly and carefully.
HINT: Make sure the engine is clear of steering gear assembly all wiring, hoses and cables.
f) Place the engine and transaxle assembly on to the stand.
26. SEPARATE ENGINE AND TRANSAXLE
INSTALLATION
1. ASSEMBLY ENGINE AND TRANSAXLE
2. INSTALL ENGINE AND TRANSAXLE ASSEMBLY-IN VEHICLE
a) Attach the engine sling device to the engine hangers.
b) Slowly lower the vehicle, and raise the engine into the engine compartment.
c) Keep the engine level, and align RH and LH mountings with the body bracket.
d) Install the RH engine mounting insulator with the 5 bolts and nut.
Torque:
Bolt A 45 Nm (459 kgf-cm, 33 ft. lbs.)
Bolt B and nut 52 Nm (530 kgf-cm, 38 ft. lbs.)
e) Install the liquid tube with the bolt.
f) Connect the LH engine mounting, and install the 2 bolts.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
3. INSTALL REAR ENGINE MOUNTING
a) Install the rear engine mounting bracket with the 3 bolts.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
b) Temporarily install the rear engine mounting insulator with the through bolt and lock nut.
4. INSTALL SUSPENSION MEMBER
5. INSTALL DRIVE SHAFT
6. INSTALL CENTER EXHAUST PIPE
a) Install new 2 gaskets and center exhaust pipe with the 2 springs, pipe clamp and 3 bolts.
Torque:
Bolt A 62 Nm (630 kgf-cm, 46 ft. lbs.)
Bolt B 32 Nm (330 kgf-cm, 24 ft. lbs.)
b) Install the floor brace with the 2 bolts.
c) Connect the connector for front heated oxygen sensor.
d) Install the rear heated oxygen sensor.
7. CONNECT PS PUMP TO ENGINE
8. CONNECT ENGINE WIRE TO CABIN
a) Push in the engine wire to the cabin.
b) Connect the 2 cowl wire connectors to the connectors on the bracket.
c) Connect the 4 ECM connectors.
d) Install the lower panel.
9. CONNECT ENGINE WIRE TO ENGINE COMPARTMENT
a) Connect the positive cable to the positive terminal.
b) Connect the connector to the fusible link.
c) Connect the cable clamp to the relay box.
d) Connect the connector to the relay box.
10. CONNECT TRANSAXLE CONTROL CABLE(S) TO TRANSAXLE
11. M/T:
CONNECT CLUTCH RELEASE CYLINDER TO TRANSAXLE
a) Connect the clutch release cylinder with the 2 bolts.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
b) Connect the bracket to the transaxle with the bolt.
Torque: 4.9 Nm (50 kgf-cm, 43 inch lbs.)
12. w/A/C:
CONNECT A/C COMPRESSOR TO ENGINE
a) Connect the A/C compressor to the engine with the 4 bolts.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
b) Connect the A/C compressor connector.
13. INSTALL RADIATOR ASSEMBLY
14. INSTALL GENERATOR AND DRIVE BELT
15. CONNECT TUBE, HOSE AND CONNECTOR
a) Connect the heater hose to the water hose union on the cylinder head.
b) Connect the brake booster vacuum hose.
c) Connect the heater hose to the water bypass pipe.
d) Connect the fuel tube to the fuel pipe on vehicle side.
e) Install the fuel pipe clamp.
16. INSTALL AIR CLEANER CASE
a) Install the air cleaner case and air cleaner inlet assembly with the 4 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
b) Install the air filter.
17. INSTALL AIR CLEANER CAP
a) Connect the air cleaner hose to the throttle body with the hose clamp.
b) Install the air cleaner cap to the air cleaner case.
c) Connect the 2 clamps.
d) Connect the 2 hose to the VSV for EVAP
e) Connect the PCV hose to the cylinder head.
f) Connect the MAF sensor connector.
18. CONNECT ACCELERATOR CABLE
19. INSTALL OUTER FRONT COWL TOP PANEL
20. INSTALL ENGINE UNDER COVERS
21. INSTALL HOOD
22. INSTALL BATTERY AND TRAY
23. FILL WITH ENGINE COOLANT
24. FILL WITH ENGINE OIL
25. FILL WITH TRANSAXLE OIL
26. START ENGINE AND CHECK FOR LEAKS
27. RECHECK ENGINE COOLANT AND OIL LEVELS