Engine: Service and Repair
RemovalSpecial Tools Required
- Front subframe adapter
NOTE:
- 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. Secure the hood in the wide open position by using the support rod as shown.
2. Drain the power steering system fluid.
3. Make sure you have the anti-theft codes for the radio and navigation system, then write down the frequencies for the radio's preset buttons.
4. Disconnect the negative cable from the battery first, and then the positive cable.
5. Remove the battery.
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 clamps (A), and disconnect the engine wire harness connectors (B) on the left side of the engine compartment.
9. Remove the relay bracket (A).
10. Remove the three mounting bolts (B), and loosen the mounting bolt (C), then remove the battery base (D).
11. Remove the ground cable (A), harness clamp (B) and starter motor cable (C), and unlatch the automatic transmission fluid (ATF) cooler hose clamp (D).
12. 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.
13. Relieve fuel pressure.
14. Remove the fuel feed hose (A), fuel return hose (B) and evaporative emission (EVAP) canister hose (C).
15. Remove the center console lower panel (driver's side), and pull back the carpet to expose the steering joint cover.
16. Remove the steering joint cover (A).
17. 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).
18. Disconnect the powertrain control module (PCM) connectors.
19. Disconnect the primary heated oxygen sensor (primary HO2S) connector (A).
20. Remove the harness holder (B).
21. Loosen the grommet mounting nuts (C). Turn the grommet (D) counterclockwise, then pull the engine wire harness through the bulkhead.
22. Remove the brake booster vacuum hose.
23. Remove the power steering (P/S) pump inlet hose (A) and P/S pump outlet hose (B) from the P/S pump.
24. Remove the P/S hose clamp (C).
25. Remove the battery cable (A) from the under-hood fuse/relay box, and remove the harness clamps (B).
26. Remove the alternator-compressor belt.
27. Remove the radiator cap.
28. Raise the hoist to full height.
29. Remove the front tires/wheels.
30. Remove the splash shield.
31. Loosen the drain plug in the radiator, and drain the engine coolant.
32. Drain the ATF. Reinstall the drain plug using a new washer.
33. Drain the engine oil. Reinstall the drain bolt using a new washer.
34. Remove the front subframe stiffener.
35. Remove the harness clamps (A), then remove exhaust pipe A (B).
36. Make reference marks (A) on the propeller shaft (B) and transfer shaft flange (C), then separate the propeller shaft from the transfer shaft flange.
37. Remove the shift cable.
38. Remove the transfer assembly.
39. Disconnect the tie-rod end ball joints.
40. Disconnect the suspension lower arm ball joints and stabilizer links.
41. Remove the driveshafts. Coat all precision finished surfaces with clean engine oil. Tie plastic bags over the driveshaft ends.
42. Remove the P/S hose.
43. Disconnect the power steering pressure switch connector.
44. Remove the nuts securing the transmission lower front mount and transmission lower rear mount.
45. Remove the bolts securing the rear mount.
46. Remove the A/C compressor without disconnecting the A/C hoses.
47. Lower the hoist.
48. Remove the heater hoses.
49. Remove the upper radiator hose (A), lower radiator hose (B), and ground cable (C).
50. Remove the ATF cooler hoses, then plug the ATF cooler hoses and lines.
51. Remove the radiator.
52. Hang the A/C compressor with a rope as shown.
53. Attach the chain hoist to the engine as shown.
54. Remove the bolts securing the side engine mount bracket.
55. Remove the nut securing the front mount bracket.
56. Make sure the hoist brackets are positioned properly. Raise the hoist to full height.
57. Make reference marks (A) on the body across from the marks (B) on the edge of the front subframe (C).
58. Loosen the four bolts (A) holding the adjustable arms (B) of the front subframe adapter to its center plate.
59. Line up the slots in the arms with the bolt holes on the corner of the jack base, then attach the adapter to the jack base with the bolts (A) that came with the jack. Tighten all bolts securely.
60. Raise the jack to vehicle height, then attach the adapter to the front subframe using the subframe stiffener mounting bolts (B) and bolt holes.
61. Remove the six 12 x 1.25 mm bolts (A) securing the subframe stiffeners (B), the four subframe mounting bolts (C), and the stiffeners, then lower the front subframe (D).
62. Check that the engine/transmission is completely free of vacuum hoses, fuel and coolant hoses, and electrical wiring.
63. Slowly lower the engine about 150 mm (6 inch). Check once again that all hoses and wires are disconnected from the engine/transmission.
64. Lower the engine all the way. Remove the chain hoist from the engine.
65. Remove the engine from under the vehicle.
Installation
Special Tools Required
- Front subframe adapter
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. Support the front subframe with the front subframe adapter and a jack, and lift it up to the body.
4. Loosely install the four front subframe mounting bolts (A) and the six 12 x1.25 mm bolts (B), (C) with the stiffeners (D).
5. Align all reference marks (A) on the front subframe (B) with the body, then tighten the bolts on the front subframe to the specified torque.
6. Tighten the transmission lower rear mount mounting nuts (A) and transmission lower front mount mounting nuts (B).
7. Tighten the rear mount mounting bolts.
8. Lower the hoist.
9. Tighten the front mount support nut.
10. Tighten the side engine mount mounting bolts.
11. Remove the chain hoist from the engine.
12. Raise the hoist to full height.
13. Install the A/C compressor.
14. Install the power steering (P/S) hose.
15. Connect the power steering pressure switch connector.
16. Install a new set ring on the end of each driveshaft, then install the driveshafts. Make sure each ring "clicks" into place in the differential and intermediate shaft.
17. Connect the suspension lower arm ball joints, and stabilizer links.
18. Connect the tie-rod end ball joints.
19. Install the transfer assembly.
20. Install the shin cable.
21. Align the reference marks (A) on the propeller shaft (B) and transfer shaft flange (C), then install the propeller shaft.
22. Install exhaust pipe A (A); use new gaskets (B) and new self locking nuts (C).
23. Install the harness clamps (D).
24. Install the front subframe stiffener.
25. Install the splash shield.
26. Install the front tires/wheels.
27. Lower the hoist.
28. Install the radiator.
29. Install the automatic transmission fluid (ATF) cooler hoses.
30. Install the upper radiator hose (A), lower radiator hose (B), and ground cable (C).
31. Install the heater hoses.
32. Install the alternator belt.
33. Install the P/S pump inlet hose (A) and P/S hose clamp (B).
34. Install the P/S pump outlet hose (C) with a new 0ring (D).
35. Install the battery cable (A) on the under-hood fuse/relay box. then install the harness clamps (B)
36. Install the brake booster vacuum hose.
37. Push the powertrain control module (PCM) connectors through the bulkhead. Install the grommet, then tighten the grommet mounting nuts (A).
38. Install the harness holder (B).
39. Connect the primary heated oxygen sensor (primary H02S) connector (C).
40. Connect the PCM connectors.
41. Align the reference mark (A) on the steering joint and steering gearbox pinion shaft. Connect the steering joint (B) to the steering gearbox pinion shaft (C). Tighten the steering joint bolt.
42. Install the steering joint cover (D).
43. Install the fuel feed hose (A) with new washers (B).
44. Install the fuel return hose (C) and evaporative emission (EVAP) canister hose (D).
45. Install the cruise control cable, then adjust the cable.
46. Install the throttle cable, then adjust the cable.
47. Install the ATF cooler hose in the clamp (A), and install the starter motor cable (B), harness clamp (C) and ground cable (D).
48. Install the battery base (A), then install the relay bracket (B).
49. Connect the engine wire harness connectors (A) on the left side of the engine compartment, and install the harness clamps (B).
50. Install the intake air duct (A), then install the vacuum hoses (B) and breather pipe (C).
51. Install the ignition coil cover (A) and intake manifold cover (B).
52. Install the battery. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion.
53. Move the shift lever to each gear, and verify that the A/T gear position indicator follows the transmission range switch.
54. Inspect for fuel leaks. Turn the ignition switch ON (II) (do not operate the starter) so the fuel pump runs for about 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.
55. Refill the engine with engine oil.
56. Refill the transmission with ATF.
57. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
58. Refill the power steering system fluid.
59. Perform the PCM idle learn procedure, and power window control unit reset procedure.
60. Inspect the idle speed.
61. Inspect the ignition timing.
62. Check the wheel alignment.
63. Enter the anti-theft codes for the radio and the navigation system, then enter the customer's radio station presets.