Engine: Service and Repair

Engine Removal

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. Turn off the manual shut-off valve.
2. To reduce pressure in the lines, start the engine, and run it until it stalls.
3. Secure the hood in the wide open position (support rod in the lower hole).
4. Make sure you have the anti-theft code for the radio, then write down the customer's radio station presets.
5. Disconnect the negative cable from the battery first, then disconnect the positive cable.





6. Remove the intake resonator.
7. Remove the battery and battery base.





8. Remove the battery cables (A) from the fuse box, and remove the harness clamps (B).





9. Remove the intake air duct (A) and ground cable (B).





10. Remove the shift cable.





11. Remove the brake booster vacuum hose.





12. Remove the adjusting plate mounting bolt (A), locknut (B), and mounting nut (C), then remove the power steering (P/S) pump belt (D) and pump without disconnecting the P/S hoses.





13. Remove the A/C hose bracket (A) and P/S hose bracket (B).





14. Remove the throttle cable (A) and cruise control actuator cable (B) by loosening the locknuts (C), then slip 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.
15. Remove the alternator.





16. Remove the alternator lower bracket (A), then remove the A/C compressor (B) without disconnecting the A/C hoses.
17. Remove the glove box stops, then open the glove box.





18. Disconnect the powertrain control module (PCM) connectors.





19. Remove the harness clamps (A) and grommet (B), then pull the engine wire harness through the bulkhead.
20. Remove the radiator cap.
21. Raise the vehicle on the hoist to full height.
22. Remove the front tires/wheels.





23. Remove the splash shield.
24. Loosen the drain plug in the radiator, drain the engine coolant.
25. Drain the transmission fluid. Reinstall the drain plug using a new washer.
26. Drain the engine oil. Reinstall the drain bolt using a new washer.





27. Remove the exhaust pipe A/three way catalytic converter (TWC).
28. Disconnect the suspension lower arm ball joints, and stabilizer links.
29. Remove the driveshafts. Coat all precision finished surfaces with clean engine oil. Tie plastic bags over the driveshaft ends.
30. Lower the vehicle on the hoist.





31. Remove the ground cable (A), upper radiator hose (B), lower radiator hose (C), and heater hose (D).





32. Remove the heater hoses (A), pressure regulator water inlet hose B (B), and pressure regulator water outlet hose B (C).





33. Remove the fuel feed hose.





34. Disconnect the automatic transmission fluid (ATF) cooler hoses.
35. After disconnecting the hoses and lines, plug or seal them with a piece of tape or equivalent to prevent foreign materials from entering.





36. Attach the chain hoist to the engine as shown.





37. Remove the front mount mounting bolt.





38. Remove the side engine mount bracket mounting nuts.





39. Remove the transmission mount bracket mounting bolt/nuts.
40. Make sure the hoist brackets are positioned properly. Raise the vehicle on the hoist to full height.





41. Remove the rear mount mounting bolts.





42. Use a marker to make alignment marks on the reference lines (A) that align with the centers of the rear subframe mounting bolts (B).
43. Remove the front subframe.
44. Check that the engine/transmission is completely free of vacuum hoses, fuel and coolant hoses, and electrical wiring.
45. Slowly lower the engine/transmission assembly about 150 mm (6 inch). Check once again that all hoses and wires are disconnected from the engine/ transmission.
46. Lower the engine/transmission assembly all the way up. Remove the chain hoist from the engine.
47. Remove the engine/transmission assembly from under the vehicle.

Engine Installation





1. Install the accessory brackets and tighten their bolts to the specified torques.
2. Position the engine/transmission assembly 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 subframe (A). Align the reference lines (B) on the subframe with the bolt head center, then tighten the bolts.





4. Tighten the rear mount mounting bolts.
5. Lower the vehicle on the hoist.





6. Tighten the side engine mount bracket mounting nuts.





7. Tighten the transmission mount bracket mounting bolt/nuts.





8. Tighten the front mount mounting bolt.
9. Remove the chain hoist from the engine.
10. Raise the vehicle on the hoist to full height.
11. 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.
12. Connect the suspension lower arm ball joints, and stabilizer links.





13. Install the exhaust pipe A/three way catalytic converter (TWC) (A), use new gaskets (B) and new self locking nuts (C).





14. Install the splash shield.
15. Install the front tires/wheels.
16. Lower the vehicle on the hoist.





17. Install the automatic transmission fluid (ATF) cooler hoses.





18. Install a new O-ring (A) on the fuel feed housing (B). Apply silicone oil to the O-ring and install the hose.





19. Install the heater hoses (A), pressure regulator water inlet hose B (B), and pressure regulator water outlet hose (C).





20. Connect the heater hose (A), lower radiator hose (B), upper radiator hose (C), and ground cable (D).





21. Install the A/C compressor (A), then install the alternator lower bracket (B).
22. Loosely install the alternator.
23. Adjust the alternator-compressor belt tension.
24. Loosely install the power steering (P/S) pump belt and pump.
25. Adjust the P/S pump belt.
26. Install the throttle cable.
27. Adjust the throttle cable.
28. Install the cruise control actuator cable.
29. Adjust the cruise control actuator cable.





30. Install the A/C hose bracket (A) and P/S hose bracket (B).





31. Install the brake booster vacuum hose.





32. Install the shift cable (A) using the plastic washer (B), washer (C), and spring pin (D).





33. Install the intake air duct (A) and ground cable (B).





34. Install the battery cables (A) on the under-hood fuse/relay box, then install the harness clamps (B).
35. Install the battery and battery base.





36. Push the powertrain control module (PCM) connectors through the bulkhead, then install the grommet (A) and the harness clamps (B).





37. Connect the PCM connectors.
38. Install the glove box stops.





39. Install the intake resonator.
40. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion.
41. Move the shift lever to each gear, and verify that the A/T gear position indicator follows the transmission range switch.
42. Do the leak Inspection.
43. Refill the engine with new engine oil.
44. Refill the transmission with ATF.
45. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
46. Check the wheel alignment.
47. Enter the anti-theft code for the radio, then enter the customer's radio station presets.
48. Set the clock.
49. Do the PCM idle learn procedure.