Engine: Service and Repair

Important Operations - Removal


- Carefully remove the piping, hoses, wiring harness connectors, control cables, and control rods from the engine.





- When disconnecting vacuum hoses, use tags to identify how they should be reconnected.

- Remove the clutch slave cylinder the back up lamp switch connector, (Manual transmission) solenoid switches and other switches connector (Automatic transmission) and the speedometer cable from the transmission.





- The transmission must be separated from the engine before the engine is hoisted from the engine compartment.



Removal steps

1. Battery





1) Remove the battery cable (1) and the grounding cable (2) from the battery terminals. Remove the battery clamp (3)

Note: Be careful not to short the battery with your wrench or another tool at this time.

2) Remove the battery.
3) Remove the battery cable at the starter motor and the grounding cable at the cylinder body.

2. Engine Hood





- Mark the engine hood (1) and the engine hood hinge (2) before removing the engine hood. This will facilitate installation of the engine hood to its original position.






3. Remove the undercover and drain the cooling system by opening the drain plugs on the radiator and on the cylinder block.
4. Drain the engine oil.
5. Remove the air cleaner duct hose.


Removal of parts at left side of engine

1. Disconnect the air pump hose from air cleaner.
2. Disconnect the vacuum hose from master vac.
3. Disconnect the 02 sensor, air flow sensor and generator wiring at the connector.
4. Remove the two nuts connecting the exhaust pipe to the engine exhaust manifold, and disconnect the exhaust pipe.
5. Disconnect the rubber hose at air switching valve.
6. Disconnect the heater hoses at heater core tubes.
7. Disconnect the power steering hose at the oil pump tank.
8. Remove the engine mounting nut.


Removal of parts at right side of engine




1. Disconnect the rubber hoses at canister.





2. Disconnect the accelerator control cable and TV cable (A/T Model) from the throttle valve.
3. Disconnect I. TEC harness, thermo-unit, oil pressure switch wiring at the connector.
4. Disconnect the starter motor connections.





5. Disconnect the fuel hoses from pressure regulator and injection pipe.
6. Disconnect the back-up light switch and transmission switches wiring at the connector on the rear part of the engine.
7. Remove the engine mounting nut.


Removal of parts at front of engine

Note: Remove the transmission from the engine before engine removal from vehicle.

1. Disconnect compressor flex hoses (If equipped).
2. Disconnect the radiator reserve tank pipe at the radiator side.
3. Disconnect the radiator upper and lower hoses from the outlet pipe and from the radiator, respectively.
4. Remove the radiator attaching bolts, and remove radiator.
5. Remove fan blade assembly.


Removal of interior parts

1. Take out the gearshift lever assembly.


Removal of parts under the floor

1. Remove the parking brake return spring and disconnect brake cable.
2. Disconnect the propeller shaft from the transmission.





3. Remove the clutch slave cylinder.
4. Remove the engine stiffener.
5. Remove the front side exhaust pipe bracket from the transmission.
6. Disconnect the mounting clamp of front side exhaust pipe.
7. Disconnect the speedometer cable.
8. Remove the rear speedometer cable.






9. Install plug to transmission rear cover to prevent oil from draining.
10. Remove the #3 cross member from chassis frame and support the transmission assembly using a jack or equivalent.






11. Remove the transmission to engine attaching bolts.

Note: Check that the engine is slightly lifted before removing the rear engine mounting bolts.


Engine removal





1. Check to make certain all the parts have been removed or disconnected from the engine.
2. Raise the engine toward front of the vehicle.
3. Remove the transmission assembly from the engine.



Installation steps

- To install the engine in the vehicle, reverse the removal procedure.


Preparation for engine installation

1. Check harnesses for damage and correct or replace with new ones as necessary.
2. Check the engine mounting rubbers for looseness or damage and tighten or replace with new ones as necessary.


Steps to be followed after engine installation

1. Fill the engine cooling system.
2. Fill the engine crankcase with engine oil.
3. Start and let the engine run at idle and check for leakage.