Engine: Service and Repair
Engine RemovalNOTE: Use fender covers to avoid damaging painted surfaces.
- To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
- Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring or hoses, or interfere with other parts.
1. Remove the support struts from the hood, and prop the hood in a vertical position.
2. Drain the power steering system fluid.
3. Make sure you have the anti-theft code for the radio and the navigation system, then write down the frequencies for the radio's preset buttons.
4. Disconnect the battery negative terminal first, then the positive terminal.
5. Remove the battery and battery tray.
6. Remove the intake manifold cover (A) and ignition coil cover (B).
7. Remove the vacuum hoses (A) and breather pipe (B), then remove the intake air duct (C).
8. Remove the harness clips (A), and disconnect the engine wire harness connectors (B) on the left side of the engine compartment.
9. Remove the ground cable (A), relay bracket (B), and harness clip (C), then remove the battery base (D).
10. Remove the harness clip (A) and starter motor cable (B), and unlatch the ATF cooler hose clamp (C).
11. Remove the throttle cable (A) and cruise control cable (B) by loosening the locknuts (C), then slipping the cable ends out of the accelerator linkage. Take care not to bend the cables when removing them. Always replace any kinked cable with a new one.
12. Relieve fuel pressure.
13. Remove the fuel feed hose (A), fuel return hose (B), and Evaporative Emission (EVAP) canister hose (C).
14. Remove the center console lower panel (driver's side), and pull back the carpet to expose the steering joint cover.
15. Remove the steering joint cover (A).
16. Make a reference mark (B) across the steering joint and steering gearbox pinion shaft. Remove the steering joint bolt (C), and disconnect the steering joint from the steering gearbox pinion shaft (D).
17. Disconnect the Powertrain Control Module (PCM) connectors.
18. Disconnect the primary heated oxygen sensor (primary HO2S) connector (A), and remove the harness clamps (B).
19. Loosen the grommet mounting nuts (C). Turn the grommet (D) counterclockwise, then pull the engine wire harness through the bulkhead.
20. Remove the brake booster vacuum hose.
21. Remove the power steering (P/S) pump inlet hose (A) and P/S pump outlet hose (B) from the P/S pump.
22. Remove the P/S hose clamp (C).
23. Remove the battery cable (A) from the under-hood fuse relay box, and remove the harness clips (B).
24. Use the belt tension release arm (A) to move the auto-tensioner (B), then remove the alternator belt (C).
25. Remove the radiator cap.
26. Raise the hoist to full height.
27. Remove the front tires/wheels.
28. Remove the splash shield.
29. Loosen the drain plug in the radiator, and drain the engine coolant.
30. Drain the ATF. Reinstall the drain plug using a new washer.
31. Drain the engine oil. Reinstall the drain bolt using a new washer.
32. Remove the front sub-frame stiffener.
33. Remove the harness clip (A), then remove exhaust pipe A (B).
34. Make reference marks (A) on the propeller shaft (B) and transfer shaft flange (C), then separate the propeller shaft from the transfer shaft flange.
35. Remove the shin control cable.
36. Remove the transfer assembly.
37. Disconnect the tie-rod end ball joints.
38. Disconnect the suspension lower arm ball joints and stabilizer links.
39. Remove the driveshafts. Coat all precision finished surfaces with clean engine oil. Tie plastic bags over the driveshaft ends.
40. Remove the P/S hose.
41. Disconnect the power steering pressure switch connector.
42. Remove the nuts securing the transmission lower front mount and transmission lower rear mount.
43. Remove the bolts securing the rear mount.
44. Remove the Air Conditioning (A/C) compressor without disconnecting the A/C hoses.
45. Lower the hoist.
46. Remove the heater hoses.
47. Remove the upper radiator hose (A), lower radiator hose (B), and ground cable (C).
48. Remove the ATF cooler hoses, then plug the ATF cooler hoses and lines.
49. Remove the radiator.
50. Hang the A/C compressor with a rope.
51. Attach the chain hoist to the engine.
52. Remove the bolts securing the side engine mount bracket.
53. Remove the nut securing the front mount bracket.
54. Make sure the hoist brackets are positioned properly. Raise the hoist to full height.
55. Make reference marks (A) on the body next to the marks (B) on the front sub-frame (C).
56. Remove the front sub-frame.
57. Check that the engine/transmission is completely free of vacuum hoses, fuel and coolant hoses, and electrical wiring.
58. Slowly lower the engine approximately 150 mm (6 inch). Check once again that all hoses and wires are disconnected from the engine/transmission.
59. Lower the engine all the way. Remove the chain hoist from the engine.
60. Remove the engine from under the vehicle.
Engine Installation
1. Install the accessory brackets, and tighten their bolts and nuts to the specified torques.
2. Position the engine under the vehicle. Attach the chain hoist to the engine, then lift the engine into position in the vehicle.
NOTICE: Reinstall the mounting bolts/support nuts in the sequence given. Failure to follow this sequence may cause excessive noise and vibration, and reduce bushing life.
3. Install the front sub-frame (A). Align the reference marks (B) on the front sub-frame with the body, then tighten the bolts.
4. Tighten the transmission lower rear mount mounting nuts (A) and transmission lower front mount mounting nuts (B).
5. Tighten the rear mount mounting bolts.
6. Lower the hoist.
7. Tighten the front mount support nut.
8. Tighten the side engine mount mounting bolts.
9. Remove the chain hoist from the engine.
10. Raise the hoist to full height.
11. Install the A/C compressor.
12. Install the P/S hose.
13. Connect the power steering pressure switch connector.
14. Install a new spring clip on the end of each driveshaft, then install the driveshafts. Make sure each clip "clicks" into place in the differential and intermediate shaft.
15. Connect the suspension lower arm ball joints, and stabilizer links.
16. Connect the tie-rod end ball joints.
17. Install the transfer assembly.
18. Install the shift cable.
19. Align the reference marks (A) on the propeller shaft (B) and transfer shaft flange (C), then install the propeller shaft.
20. Install exhaust pipe A (A); use new gaskets (B) and new self locking nuts (C).
21. Install the primary HO2S harness in the clamp (D).
22. Install the front sub-frame stiffener.
23. Install the splash shield.
24. Install the front tires/wheels.
25. Lower the hoist.
26. Install the radiator.
27. Install the ATF cooler hoses.
28. Install the upper radiator hose (A), lower radiator hose (B), and ground cable (C).
29. Install the heater hoses.
30. Install the alternator belt.
31. Install the P/S pump inlet hose (A) and P/S hose clamp (B).
32. Install the P/S pump outlet hose (C) with a new O-ring (D).
33. Install the battery cable (A) on the under-hood fuse/relay box, then install the harness clips (B).
34. Install the brake booster vacuum hose.
35. Push the PCM connectors through the bulkhead. Install the grommet, then tighten the grommet mounting nuts (A).
36. Install the harness clips (B).
37. Connect the primary H02S connector (C).
38. Connect the PCM connectors.
39. Align the reference mark (A) on the steering joint and steering gearbox pinion shah. Connect the steering joint (B) to the steering gearbox pinion shaft (C). Tighten the steering joint bolt.
40. Install the steering joint cover (D).
41. Install the fuel feed hose (A) with new washers (B).
42. Install the fuel return hose (C) and EVAP canister hose (D).
43. Install the cruise control cable, then adjust the cable.
44. Install the throttle cable, then adjust the cable.
45. Install the ATF cooler hose in the clamp (A), and install the starter motor cable (B) and harness clip (C).
46. Install the battery base (A), then install the relay bracket (B), harness clip (C), and ground cable (D).
47. Connect the engine wire harness connectors (A) on the led side of the engine compartment, and install the harness clips (B).
48. Install the intake air duct (A), then install the vacuum hoses (B) and breather pipe (C).
49. Install the ignition coil cover (A) and intake manifold cover (B).
50. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion.
51. Move the shift lever to each gear, and verify that the A/T gear position indicator follows the transmission range switch.
52. Inspect for fuel leaks. Turn ON (II) the ignition switch (do not operate the starter) so that the fuel pump runs for approximately 2 seconds and pressurizes the fuel line. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
53. Refill the engine with engine oil.
54. Refill the transmission with ATF.
55. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
56. Refill the power steering system fluid.
57. Check the wheel alignment.
58. Enter the anti-theta code for the radio and the navigation system, then enter the customer's radio station presets.