Engine: Service and Repair

REMOVAL
1. REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. DRAIN ENGINE OIL
4. REMOVE HOOD





5. REMOVE OUTER COWL TOP PANEL ASSEMBLY
a. Remove the 3 nuts and wiper arm and blade assemblies.
b. Apply gummed tape at the bottom of the front windshield glass to protect it.
c. Remove the head to cowl top seal.
d. Remove the clip, and remove the cowl top ventilator louver. Remove the RH and LH ventilator louvers.
e. Disconnect the wiper motor connector and wire.
f. Remove the 5 bolts and wiper motor with the wiper link.
g. Remove the 9 bolts and outer cowl top PANEL.
6. REMOVE BATTERY AND TRAY
7. REMOVE Y-BANK COVER





8. REMOVE AIR CLEANER CAP AND AIR CLEANER CASE
a. Disconnect the MAF meter connector and wire clamp.
b. Disconnect the these hoses:
^ EVAP hose from EVAP pipe
^ PCV hose from LH cylinder head cover
c. Disconnect the 2 clamps, and disconnect the air cleaner cap from the air cleaner case.
d. Loosen the 2 hose clamps, and disconnect the air cleaner hose from the throttle body.
e. Disconnect the accelerator cable from the clamp.
f. Remove the air cleaner cap with the hose.
g. Remove the air filter.
h. Remove the 3 bolts and air cleaner case.
9. REMOVE CRUISE CONTROL ACTUATOR
a. Disconnect the cable from the throttle body.
b. Disconnect the connector and clamp.
c. Remove the 2 bolts, nut and actuator.





10. REMOVE FRONT UPPER SUSPENSION BRACE
a. Remove the bolt and disconnect the brake master cylinder reservoir.
b. Disconnect the engine wire.
c. Disconnect the 2 heater hoses.
d. Remove the 4 nuts and front upper suspension brace.
11. DISCONNECT CONNECTORS AND CLAMP
^ Generator wire, connector and clamp.
^ 2 ground strap connectors from RH fender apron.
^ Ground strap from LH fender apron.
^ Noise filter connector on LH fender apron.
^ Battery negative (-) cable 2 connectors from engine room junction block.
12. DISCONNECT HOSES
^ Brake booster vacuum hose from air intake chamber.
^ Heater hose from intake manifold.
^ Heater hose from water inlet housing.
^ Fuel inlet hose from fuel pipe.

CAUTION: Perform disconnecting operations of the fuel tube connector (quick type) after observing the precautions.

^ Purge hose from pipe on emission control valve set.
^ 2 vacuum hoses from vacuum tank for ACIS.
^ Upper radiator hose from water outlet.
^ Lower radiator hose from water inlet pipe.
^ 2 A/T cooler hoses from 2 pipes on transaxle.
13. DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY





14. DISCONNECT ENGINE WIRE FROM CABIN
a. Remove the ECM.
b. Remove the 2 nuts holding the engine wire retainer to the cowl panel.
c. Pull out the engine wire.
15. REMOVE GENERATOR FROM ENGINE
16. REMOVE A/C COMPRESSOR FROM ENGINE
17. DISCONNECT A/T SHIFT CONTROL CABLE FROM TRANSAXLE





18. REMOVE NO.2 FRONT EXHAUST PIPE
a. Remove the 2 bolts holding the No.2 front exhaust pipe to the WU-TWC.
b. Remove the 2 bolts holding the No.2 front exhaust pipe to the front exhaust pipe.
c. Remove the No.2 front exhaust pipe and 2 gaskets.





19. REMOVE FRONT EXHAUST PIPE
a. Remove the 2 nuts holding the front exhaust pipe to the RH exhaust manifold.
b. Remove the 2 bolts and 2 springs holding the front exhaust pipe to the center exhaust pipe.
c. Remove the front exhaust pipe and 2 gaskets.
20. REMOVE RH FENDER APRON SEAL
21. DISCONNECT STABILIZER BAR LINKS
22. 2WD: REMOVE DRIVE SHAFTS
23. 4WD: REMOVE DRIVE SHAFTS
24. 4WD: REMOVE FRONT PROPELLER SHAFT
25. DISCONNECT INTERMEDIATE SHAFT ASSEMBLY





26. DISCONNECT VSV FROM FRONT ENGINE MOUNTING INSULATOR
a. Disconnect the vacuum hoses from the front frame assembly.
b. Disconnect the VSV connector and clamp.
c. Remove the screw and disconnect the VSV.
27. DISCONNECT PS HOSE FROM PS OIL RESERVOIR





28. DISCONNECT PS HOSE FROM PS RESERVOIR PIPE





29. DISCONNECT AIT OIL COOLER PIPE
Remove the bolt and disconnect the pipe from the front frame assembly.
30. DISCONNECT FENDER APRON SEALS
Remove the screws and turn over the front side of the LH and RH fender liners.





31. ATTACH ENGINE SLING DEVICE TO ENGINE HANGERS
a. Install the No.2 engine hanger in the correct direction.
Part No.:
No.2 engine hanger 12282-20020
Bolt 91642-30325
Torque: 19.5 Nm (200 kgf-cm, 14 ft. lbs.)
b. Attach the sling device to the engine hangers.

CAUTION: Do not attempt to hang the engine by hooking the chain to any other part.





32. REMOVE ENGINE MOVING CONTROL ROD AND NO.2 RH ENGINE MOUNTING BRACKET
Remove the 4 bolts, control rod and mounting bracket.





33. REMOVE LOWER BRACES
Remove the 8 bolts and 4 lower braces.





34. REMOVE ENGINE, TRANSAXLE AND FRONT FRAME ASSEMBLY FROM VEHICLE
Lower the engine out of the vehicle slowly and carefully.

NOTICE: Make sure the engine is clear of all wiring, hoses and cables.





35. DISCONNECT PS VANE PUMP FROM ENGINE
a. Disconnect the PS oil pressure switch connector.
b. Remove the 3 bolts, and disconnect the PS pressure tube.
c. Loosen the 2 bolts, and remove the drive belt.
d. Remove the 2 bolts, and disconnect the PS vane pump from the engine.





36. 4WD:
REMOVE FRONT STABILIZER
Remove the 4 bolts and stabilizer.





37. 4WD:
REMOVE PS GEAR ASSEMBLY
a. Disconnect the PS hose from the pipe.
b. Remove the 2 bolts, nut and PS gear assembly.
38. REMOVE FRONT FRAME ASSEMBLY





a. Remove the 3 bolts holding the front engine mounting insulator to the front frame assembly.





b. Remove the 4 bolts and engine mounting absorber.





c. Remove the 4 bolts holding the transaxle to the LH engine mounting insulator.








d. Remove the nut holding the rear engine mounting bracket to the rear engine mounting insulator.
e. Remove the front frame assembly.





39. REMOVE FRONT ENGINE MOUNTING INSULATOR FROM ENGINE
Remove the 4 bolts and mounting insulator.








40. REMOVE REAR ENGINE MOUNTING BRACKET FROM ENGINE
Remove the 4 bolts and the mounting bracket.
41. 2WD: SEPARATE ENGINE AND TRANSAXLE
42. 4WD: SEPARATE ENGINE AND TRANSAXLE

INSPECTION





1. INSPECT FRONT ENGINE INSULATOR
a. Using MITYAC (Hand-Held Vacuum Pump), apply vacuum of 80 kPa (600 mm Hg, 25 inch Hg) and allow it to stand for 1 minutes.
b. Check that there is no change in the needle movement.
c. Check that there is no fluid leakage caused by a break of a lower diaphragm.
If the operation is not as specified, replace the insulator.
2. INSPECT VSV FOR ACTIVE CONTROL ENGINE MOUNT





a. Inspect the VSV for open circuit. Using an ohmmeter, check that there is continuity between the terminals.
Resistance: 18 - 22 ohms at 20°C (68°F)
If there is no continuity, replace the VSV.





b. Inspect VSV for ground. Using an ohmmeter, check that there is no continuity between each terminal and the body. If there is continuity, replace the VSV.
c. Inspect VSV operation.





1. Check that air flows from port G to port E.





2. Apply battery positive voltage across the terminals.
3. Check that air flows from port F to port E.
If operation is not as specified, replace the VSV.
3. INSPECT VACUUM TANK

INSTALLATION








1. 2WD: ASSEMBLE ENGINE AND TRANSAXLE
2. 4WD: ASSEMBLE ENGINE AND TRANSAXLE
3. INSTALL REAR ENGINE MOUNTING BRACKET
Install the mounting bracket with the 4 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)





4. INSTALL FRONT ENGINE MOUNTING INSULATOR
Install the mounting insulator with the 4 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
5. INSTALL FRONT FRAME ASSEMBLY








a. Connect the rear engine mounting bracket with the nut.
Torque: 87 Nm (890 kgf-cm, 64 ft. lbs.)





b. Connect the LH engine mounting insulator with the 4 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)





c. Install the engine mounting absorber with the 4 bolts.
Torque: 48 Nm (490 kgf-cm, 35 ft. lbs.)





d. Connect the front engine mounting insulator with the 3 bolts.
Torque: 80 Nm (820 kgf-cm, 59 ft. lbs.)





6. 4WD: INSTALL PS GEAR ASSEMBLY
a. Install the PS gear assembly with the 2 bolts and nut.
Torque: 181 Nm (1,850 kgf-cm, 134 ft. lbs.)
b. Connect the PS hose to the pipe.





7. 4WD: INSTALL FRONT STABILIZER
Install the stabilizer with the 4 bolts.
Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)





8. INSTALL PS VANE PUMP
a. Install the PS vane pump with the 2 bolts.
Torque: 43 Nm (440 kgf-cm, 31 ft. lbs.)
b. Install the drive belt.
c. Connect the PS pressure tube with the 3 bolts.
d. Connect the PS oil pressure switch connector.





9. INSTALL ENGINE TRANSAXLE AND FRONT FRAME ASSEMBLY IN VEHICLE
a. Attach the engine sling device to the engine hangers.
b. Lift the engine into the engine compartment.





10. INSTALL LOWER BRACES
Install the 4 lower braces with the 8 bolts.
Torque:
Bolt A: 181 Nm (1,850 kgf-cm, 134 ft. lbs.)
Bolt B: 32 Nm (330 kgf-cm, 24 ft. lbs.)
11. INSTALL NO.2 RH ENGINE MOUNTING BRACKET AND ENGINE MOVING CONTROL ROD





a. Temporarily install the No.2 RH engine mounting bracket and engine moving control rod with the 3 bolts.





b. Install and tighten the bolt (A).
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
c. Tighten the other 3 bolts (B, C, D).
Torque: Bolts B and C: 64 Nm (650 kgf-cm, 47 ft. lbs.)
Bolt D: 32 Nm (320 kgf-cm, 23 ft. lbs.)
12. REMOVE ENGINE SLING DEVICE
13. CONNECT FENDER APRON SEALS





14. CONNECT A/T OIL COOLER PIPE
Install the A/T oil cooler pipe to the front frame assembly with the bolt.





15. CONNECT PS HOSE TO PS RESERVOIR PIPE





16. CONNECT PS HOSE TO PS OIL RESERVOIR
17. CONNECT VSV FOR ACM
a. Install the VSV with the screw.
b. Connect the vacuum hoses to the front frame assembly.
c. Connect the VSV connector and clamp.
18. CONNECT INTERMEDIATE SHAFT ASSEMBLY
19. 2WD: INSTALL DRIVE SHAFTS
20. 4WD: INSTALL DRIVE SHAFTS
21. CONNECT STABILIZER BAR LINKS
22. 4WD: INSTALL PROPELLER SHAFT
23. INSTALL RH FENDER APRON SEAL





24. INSTALL FRONT EXHAUST PIPE
a. Temporarily install 2 new gaskets and the front exhaust pipe with the 2 bolts, 2 springs and 2 nuts.
b. Tighten the 2 nuts holding the RH exhaust manifold to the front exhaust pipe.
Torque: 62 Nm (630 kgf-cm, 46 ft. lbs.)
c. Tighten the 2 bolts holding the front exhaust pipe to the center exhaust pipe.
Torque: 62 Nm (630 kgf-cm, 46 ft. lbs.)





25. INSTALL NO.2 FRONT EXHAUST PIPE
a. Temporarily install 2 new gaskets and the No.2 front exhaust pipe with the 4 bolts.
b. Tighten the 2 bolts holding the WU-TWC to the No.2 front exhaust pipe.
Torque: 56 Nm (560 kgf-cm, 41 ft. lbs.)
c. Tighten the 2 bolts holding the No.2 front exhaust pipe to the front exhaust pipe.
Torque: 56 Nm (560 kgf-cm, 41 ft. lbs.)
26. CONNECT A/T SHIFT CONTROL CABLE TO TRANSAXLE
27. INSTALL A/C COMPRESSOR
28. INSTALL GENERATOR
29. CONNECT ENGINE WIRE TO CABIN
a. Push in the engine wire through the cowl panel.
b. Install the 2 nuts holding the engine wire retainer to the cowl panel.
c. Install the ECM.
30. CONNECT ACCELERATOR CABLE TO THROTTLE BODY
31. CONNECT HOSES
^ Brake booster vacuum hose to air intake chamber
^ Heater hose to intake manifold
^ Heater hose to water inlet housing
^ Fuel inlet hose to fuel pipe

CAUTION: Perform connecting operations of the fuel tube connector (quick type) after observing the precautions.

^ Purge hose to pipe on emission control valve set
^ 2 vacuum hoses to vacuum tank for ACIS
^ Upper radiator hose to water outlet
^ Lower radiator hose to water inlet pipe
^ 2 A/T cooler hoses to 2 pipes on transaxle
32. CONNECT CONNECTORS AND CLAMP
^ Generator wire, connector and clamp
^ 2 ground strap connectors to RH fender apron
^ Ground strap to LH fender apron
^ Noise filter connector on LH fender apron
^ Battery negative (-) cable





33. INSTALL FRONT UPPER SUSPENSION BRACE
a. Install the front upper suspension brace with the 4 nuts.
Torque: 80 Nm (810 kgf-cm, 59 ft. lbs.)
b. Connect the 2 heater hoses.
c. Connect the engine wire clamp.
d. Install the brake master cylinder reservoir with the bolt.
34. INSTALL CRUISE CONTROL ACTUATOR
35. INSTALL AIR CLEANER CAP AND AIR CLEANER CASE
36. INSTALL V-BANK COVER
37. INSTALL BATTERY TRAY AND BATTERY
38. INSTALL OUTER COWL TOP PANEL ASSEMBLY
a. Install the outer cowl top PANEL with the 9 bolts.
b. Install the wiper motor with the wiper link with the 5 bolts.
c. Connect the wiper motor wire and connector.
d. Install the cowl top ventilator louver with the clip. Install the RH and LH ventilator louvers.
e. Install the head to cowl top seal.
f. Install the wiper arm and blade assemblies with the 3 nuts.
Torque: 24 Nm (245 kgf-cm, 18 ft. lbs.)
39. INSTALL HOOD
40. INSTALL ENGINE UNDER COVER
41. FILL ENGINE WITH OIL
42. FILL WITH ENGINE COOLANT
43. START ENGINE AND CHECK FOR LEAKS
44. BLEED POWER STEERING SYSTEM
45. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
46. RECHECK ENGINE COOLANT AND OIL LEVELS