Engine: Service and Repair
Make sure jacks and safety stands are placed properly and hoist brackets are attached to the correct positions on the engine.Make sure the car will not roll off stands and fall while you are working under it.
CAUTION:
Use fender covers to avoid damaging painted surfaces.
Unspecified items are common.
Unplug the wiring connectors carefully while holding the coupler and the connector portion to avoid damage.
Mark all wiring and hoses to avoid disconnection.
Also, be sure that they do not contact other wiring or hoses or interfere with other parts.
NOTE: Anti-theft radios have a coded theft protection circuit. Be sure to get the customer's code number before
Disconnecting the battery.
Removing the radio.
After service, reconnect power to the radio and turn it on. When the word "CODE" is displayed, enter the customer's 5-digit code to restore radio operation.
1. Disarm airbag system as described under Air Bags and Seat Belts / Air Bags (Supplemental Restraint Systems) / Airbag System Disarming.
2. Remove battery, then radiator cap.
3. Raise and support vehicle.
4. Remove undercover splash shield.
5. Drain coolant, transaxle fluid and differential fluid.
CAUTION: Do not over tighten the drain bolt.
6. Lower vehicle, remove hood stay, then move hood to vertical position.
7. Remove engine strut bar, bracket, and suction pipe clamp.
8. Remove battery tray.
Fig. 7 Relay Box Removal:
9. Disconnect engine electrical connectors, remove the No. 56 (7.5 A) fuse in the under-hood fuse/ then remove relay box, Fig. 7.
10. Remove cylinder block ground cable, then battery cable from starter motor "B" terminal.
11. Remove throttle cover and throttle cable locknut, then cable end from throttle bracket and accelerator linkage.
NOTE: Take care not to bend the cable when removing it. Always replace any kinked cable with a new one. Adjust the throttle cable when installing.
12. Remove air cleaner and air duct.
13. Remove igniter (ICM) connector, harness bracket and engine ground cable.
14. Disconnect emission control unit electrical connectors, then remove control unit. Do not disconnect vacuum hoses. Disconnect four engine wire harness connectors and clamps.
Fig. 8 Fuel Pressure Relief:
15. Cover fuel filter with suitable shop rag, then slowly loosen fuel filter service bolt about one turn to relieve fuel pressure, Fig. 8.
CAUTION:
Do not smoke while working on the fuel system. Keep open flame away from work area. Drain fuel only into an approved container.
Before disconnecting any fuel line, the fuel pressure should be relieved as described above.
Place a shop towel over the fuel filter to prevent pressurized fuel from spraying over the engine.
16. Remove fuel feed hose.
17. Remove pressure control valve fuel return hose.
18. Disconnect brake booster vacuum hose.
19. Remove the evaporative emission (EVAP) purge control hose and EVAP vacuum hose from the install pipes.
20. Disconnect transaxle harness, located at LH rear of engine compartment, electrical connector, then remove harness bracket.
21. Disconnect radiator hoses, ATF cooler lines, thermosensor electrical connector and cooling fan electrical connector.
22. Remove radiator assembly.
23. Remove vacuum pipe, emission device solenoid valve and air tank.
24. Remove the TCS lower bracket from the power steering bracket and the TCS control valve assembly.
25. Remove power steering belt and pump, then position aside. Do not disconnect power steering hoses.
NOTE: Do not disconnect power steering hose.
26. Remove front wheels, then damper forks.
27. Using ball joint tool No. 07MAC-SL00200 or equivalent, disconnect lower ball joints.
28. Disconnect driveshafts, then using suitable wire, suspend driveshafts.
CAUTION:
- Do not pull on the driveshaft, as the CV joint may come apart.
- Use care when prying out the assembly and pull it straight to avoid damaging the differential oil seal or intermediate shaft dust seal.
NOTE: Coat all precision finished surfaces with clean engine oil or grease. Tie plastic bags over the driveshaft ends.
29. Remove rear beam lower plate.
30. Remove vehicle speed sensor/power steering speed sensor. Do not disconnect hoses.
31. Remove exhaust pipe and joint pipe assembly.
32. On models equipped with A/C, remove A/C compressor and belt, leaving refrigerant lines attached.
33. On models equipped with manual transaxle, remove clutch slave cylinder from transmission. Do not disconnect clutch hose.
34. Disconnect shift rod and shift lever torque rod.
35. On models equipped with automatic transaxle, disconnect shift control cable.
36. On all models, remove engine mid mount attaching nuts and bolts.
CAUTION: After loosening the special nuts, be sure to replace them with new ones.
37. Remove rear transaxle mounting bracket.
38. Remove the damper and center bracket.
39. Remove front engine mount attaching nuts.
40. Remove EGR passage bolt, then install suitable engine lifting equipment.
41. Ensure engine is free of hoses and electrical connectors.
42. Remove engine assembly.
43. Remove the damper and center bracket.
44. Check that the engine/transmission is completely free of vacuum hoses, fuel and engine coolant hoses, and electrical wiring.
45. Slowly raise the engine approximately 150 mm (6 in). Check once again that all hoses and wires have been disconnected from the engine/transmission assembly.
CAUTION: Take care not to bend the suction pipe.
46. Raise the engine/transmission assembly all the way and remove it from the car.
CAUTION: Take care not to bend the suction pipe.
47. Install the engine in the reverse order of removal. After the engine is in place:
Torque the engine mount bolts/nuts in sequence shown below.
CAUTION: Failure to tighten the bolts in the proper sequence can cause excessive noise and vibration, and reduce bushing life: check that the bushings are not twisted or offset. Check that the spring clip on the end of each driveshaft clicks into place.
CAUTION: Use new spring clips.
(a) Bleed air from the cooling system at the bleed bolt with the heater valve open.
(b) Adjust the throttle cable.
(c) Check the clutch pedal free play.
(d) Check that the transmission shifts into gear smoothly.
(e) Adjust the tension of the following drive belts.
(f) Alternator belt.
(g) P/s pump belt.
(h) A/C compressor belt.
(i) Clean battery posts and cable terminals with sandpaper, assemble, then apply grease to prevent corrosion.
(j) Inspect for fuel leakage.
After assembling fuel line parts, turn on the ignition switch (do not operate the starter) so that the fuel pump operates for approximately two seconds and the fuel line pressurizes. Repeat this operation two or three times and check for fuel leakage at any point in the fuel line.
Engine Mount Bolts and Nuts Tightening Sequence:
CAUTION: After loosening the special nuts, be sure to replace them with new ones.
NOTE: Tighten the mounting bolts/nuts in the numbered sequence as shown (1-13).
Mount and Bracket Bolts/Nuts Torque Value Specifications:
CAUTION: After loosening the special nut, be sure to replace them with new ones.
Additional Mount Bolts Torque Value Specifications:
Sub Frame Mount Bolts Torque Value Specifications:
CAUTION: After loosening the special bolts, be sure to replace them with new ones.
Fig. 9 Engine & Transaxle Mount Tightening Sequence:
48 Reverse procedure to install. Torque engine and transaxle mounts in sequence to specifications, Fig. 9.
49. Restore coded theft protection system and rearm airbag.