Engine: Service and Repair

ENGINE AND TRANSAXLE ASSEMBLY

REMOVAL

CAUTION
- Make sure jacks and safety stands are placed properly.
- Make sure the vehicle will not roll off stands and fall while you are working under it.
- Use fender covers to avoid damaging painted surface.
- Unplug the wiring connectors carefully while holding the connector portion to avoid damage.
- 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 hood.
2. Remove the engine cover.





3. Remove the battery.





4. Remove the radiator grille upper cover.





5. Remove the under cover.





6. Drain engine coolant.
Remove the radiator cap to speed draining.





7. Remove the ATF oil cooler pipe hoses.





8. Remove the radiator upper hose and the coolant reservoir tank hose.





9. Remove the radiator lower hose.





10. Remove the cooling fan motor connector.





11. Remove the triple pressure switch.
12. Recover refrigerant and remove the high pressure pipe bolts.









13. Remove the radiator bracket.
14. Remove the radiator from engine compartment.





15. Remove the intake air duct and air cleaner housing.
A. Remove the air-flow sensor connector.
B. Remove the air cleaner assembly.
C. Remove the breather hose.
16. Remove the coolant reservoir tank hose.
17. Remove the ground cable from intake manifold.





18. Remove the accelerator pedal cable and the auto cruise control.
19. Remove the engine wire harness connectors.





A. Remove the HO2S (Heated Oxygen sensor) connectors, the TPS (Throttle Position Sensor) connector and the idle speed actuator connector.





B. Remove the IFS (Igniting Failure Sensor), the knock sensor connector and the injection connector.





C. Remove the ECT (Engine Coolant Temperature) sensor connector, the MAPS (Manifold Absolute Pressure Sensor) connector (B), the CMPS (Camshaft Position Sensor) connector and the CKPS (Crankshaft Position Sensor).





D. Remove the power steering switch connectors.
E. Remove the alternator connector and the starter motor S terminal connector.





F. Remove the PCSV (Purge Control Solenoid Valve) connector, the oil pressure switch connector, the HO2S (Heated Oxygen sensor) connectors and the ignition coil connector.
20. Remove the related hoses.
21. Remove the air conditioning compressor connector.





22. Remove the low pressure pipe bolt.





23. Remove the brake booster vacuum hose and the heater hoses.
24. Remove the fuel hoses.
25. Drain power steering oil.





26. Remove the power steering oil hose and power steering pressure hose.
27. Remove the ground cable from cylinder block.
28. Remove the alternator B terminal, starter motor B terminal.









29. Remove the front muffler.
Tightening torque: 42.2 - 60.8 N.m (4.3 - 6.2 kgf.m, 31.1 - 44.8 lb-ft)









30. Remove the ATF (Automatic Transaxle Fluid) oil cooler pipe fixing bolt.









31. Remove the propeller shaft.





32. Remove the shift cable assembly after removing the pins.
33. Remove the transaxle wire harness connectors and control cable.









A. Remove the control cable.
Remove the input speed sensor.





B. Remove the solenoid valve connector.





C. Remove the transfer speed sensor connector, the transfer speed sensor clutch coil and the transfer solenoid for TOD (Torque on Demand).





D. Remove the inhibitor switch connector, ATF pressure switch connectors.





E. Remove the automatic transmission terminals.

34. Support the transmission on a jack.





35. Remove the cross member.

NOTE: Tilt the automatic transmission with the transfer a little by lowering the jack. It can make the transaxle mounting bolts be removed easily.





36. Remove the start motor mounting bolts.
37. Remove the transmission mounting bolts.





38. Remove the service hole cover for loosening the drive plate bolts.





39. Remove the drive plate bolts. (6EA)
40. Remove the cowl top cover and the wiper assembly with its motor.
41. Remove the engine mounting insulator and the engine mounting bracket fixing nut. (LH included)
Tightening torque: 88.3 - 107.9 N.m (9.0 - 11.0 kgf.m, 65.1 - 79.6 lb-ft)





42. Install the engine hanger lift to the engine assembly.

INSTALLATION
Installation is in the reverse order of removal.
Perform the following:
- Adjust the shift cable.
- Adjust the throttle cable.
- Refill the engine with engine oil.
- Refill the transaxle with fluid.
- Refill the radiator and reservoir tank with engine coolant.
- Place the heater control knob on "HOT" position.
- Bleed air from the cooling system
- Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.)
- Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.
- Put the radiator cap on tightly, then run the engine again and check for leaks.
- Clean the battery posts and cable terminals with sandpaper and assemble them, then apply grease to prevent corrosion.
- Inspect for fuel leakage.
- After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.
- Repeat this operation two or three times, and then check for fuel leakage at any point in the fuel line.