Engine: Service and Repair

REMOVAL
1. REMOVE BATTERY AND TRAY
2. REMOVE HOOD
3. REMOVE ENGINE FENDER APRON SEALS
4. DRAIN ENGINE COOLANT
5. DRAIN ENGINE OIL





6. REMOVE V-BANK COVER
a. Using a 5 mm hexagon wrench, remove the 3 cap nuts.
b. Loosen the V-bank cover fastener counterclockwise. Remove the V-bank cover.
7. DISCONNECT ACCELERATOR CABLE
8. REMOVE AIR CLEANER CAP ASSEMBLY AND AIR CLEANER CASE
9. REMOVE CRUISE CONTROL ACTUATOR
10. REMOVE RADIATOR





11. REMOVE FRONT EXHAUST PIPE
a. Remove the 2 bolts holding the support stay to the support bracket.
b. Remove the 2 bolts and 2 compression springs holding the front exhaust pipe to the center exhaust pipe.
c. Remove the 4 nuts holding the front exhaust pipe to the exhaust manifolds.
d. Remove the front exhaust pipe and 3 gaskets.
12. DISCONNECT CONNECTORS, CABLE, CLAMPS AND HOSES
a. Disconnect the noise filter connector on the LH fender apron.
b. Disconnect the generator wire and connector.
c. Disconnect the starter wire and connector.
d. Remove the bolt and disconnect the ground strap from the LH fender apron.
e. Disconnect the 2 ground strap connectors from the RH fender apron.
f. Disconnect the ground cable from battery body bracket.
g. Disconnect the engine wire protector clamp from battery body bracket.
h. Disconnect the engine wire clamp from the bracket on the RH fender apron.
i. Disconnect the brake booster vacuum hose from the throttle body.
j. Disconnect the engine coolant reservoir hose from the water outlet.
k. Disconnect the heater hose from the intake manifold.
l. Disconnect the heater hose from the water inlet housing.
m. Disconnect the fuel inlet hose from the fuel filter.

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

n. Disconnect the EVAP hose assembly from the pipe on the emission control valve set.
o. Disconnect the 2 vacuum hoses from the vacuum tank for the ACIS.





13. DISCONNECT ENGINE WIRE FROM CABIN
a. Remove the No.2 instrument lower panel.
b. Disconnect the 3 ECM connectors.
c. Disconnect the 3 cowl wire connectors from the connectors on the bracket.
d. Disconnect the grommet from the cowl panel, and pull out the engine wire.
14. REMOVE DRIVE SHAFTS





15. DISCONNECT A/C COMPRESSOR FROM ENGINE
a. Disconnect the A/C compressor connector.
b. Remove the drive belt.
c. Remove the 4 bolts, nut and drive belt adjusting bar bracket.
d. Disconnect the A/C compressor from the engine.
16. DISCONNECT TRANSAXLE CONTROL CABLE FROM TRANSAXLE





17. DISCONNECT PS PUMP FROM ENGINE
a. Remove the 2 nuts, and disconnect the PS pressure tube from the No.1 engine hanger.
b. Loosen the 2 bolts, and remove the drive belt.
c. Remove the 2 bolts, and disconnect the PS pump from the engine.





18. DISCONNECT TRANSAXLE FROM LH ENGINE MOUNTING INSULATOR
Remove the 4 bolts holding the transaxle to the mounting insulator.





19. DISCONNECT REAR ENGINE MOUNTING BRACKET FROM FRONT FRAME
a. Remove the 2 hole plugs.
b. Remove the 4 nuts holding the front frame to the mounting bracket.





20. REMOVE ENGINE MOUNTING ABSORBER
Remove the 4 bolts and mounting absorber.





21. DISCONNECT FRONT ENGINE MOUNTING INSULATOR FROM FRONT FRAME
Remove the 3 bolts holding the mounting insulator to the front frame.





22. ATTACH ENGINE SLING DEVICE TO ENGINE HANGERS
a. Install the No.2 engine hanger in the correct direction.





Part No.:

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.





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





24. REMOVE ENGINE AND TRANSAXLE ASSEMBLY FROM VEHICLE
a. Lift the engine out of the vehicle slowly and carefully.

NOTICE: Be careful not to hit the PNP switch. Make sure the engine is clear of all wiring, hoses and cables.

b. Place the engine and transaxle assembly onto the stand.
25. REMOVE FRONT ENGINE MOUNTING INSULATOR FROM ENGINE
Remove the 4 bolts and mounting insulator.
26. REMOVE REAR ENGINE MOUNTING INSULATOR AND BRACKET ASSEMBLY FROM ENGINE
Remove the 4 bolts, the mounting insulator and bracket assembly.
27. SEPARATE ENGINE AND TRANSAXLE

INSPECTION





1. INSPECT FRONT ENGINE MOUNTING INSULATOR
a. Using a MITYVAC (Hand-Held Vacuum Pump), apply vacuum of 80 kPa (600 mm Hg, 25 in. Hg) and allow it to stand for 1 minute.
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: 19 - 21 Ohms at 20°C (68°F)
If there is no continuity, replace the VSV.





b. Inspect the 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 the 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. ASSEMBLE ENGINE AND TRANSAXLE
2. INSTALL REAR ENGINE MOUNTING INSULATOR
Install the mounting insulator with the 4 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
3. INSTALL FRONT ENGINE MOUNTING INSULATOR
Install the mounting insulator with the 4 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)





4. INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN VEHICLE
a. Attach the engine sling device to the engine hangers.
b. Lower the engine into the engine compartment.
Tilt the transaxle downward, lower the engine and clear the LH mounting.

NOTICE: Be careful not to hit the park/neutral position switch.

c. Keep the engine level, and align RH and LH mountings with the body bracket.
5. 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. 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.)





6. CONNECT FRONT ENGINE MOUNTING INSULATOR
Connect the mounting insulator with the 3 bolts.
Torque: 80 Nm (820 kgf-cm, 59 ft. lbs.)





7. INSTALL ENGINE MOUNTING ABSORBER
Install the engine mounting absorber with the 4 bolts.
Torque: 48 Nm (490 kgf-cm, 35 ft. lbs.)





8. CONNECT REAR ENGINE MOUNTING INSULATOR
a. Connect the mounting insulator with the 4 nuts.
Torque: 66 Nm (670 kgf-cm, 48 ft. lbs.)
b. Install the 2 hole plugs.





9. CONNECT LH ENGINE MOUNTING INSULATOR
Connect the mounting insulator with the 4 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
10. REMOVE ENGINE SLING DEVICE
11. CONNECT TRANSAXLE CONTROL CABLE TO TRANSAXLE





12. INSTALL PS PUMP
a. Install the PS 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 2 nuts.





13. INSTALL A/C COMPRESSOR
a. Install the A/C compressor and drive belt adjusting bar bracket with the 4 bolts and nut.
Torque:
Bolt A: 25 Nm (250 kgf-cm, 18 ft. lbs.)
Bolt B: 18 Nm (185 kgf-cm, 13 ft. lbs.)
Nut C: 25 Nm (250 kgf-cm, 18 ft. lbs.)
b. Install the drive belt.
c. Connect the A/C compressor connector.
14. INSTALL DRIVE SHAFTS





15. CONNECT ENGINE WIRE TO CABIN
a. Push in the engine wire through the cowl panel. Install the grommet.
b. Connect the 3 engine ECM connectors.
c. Connect the 3 cowl wire connectors to the connectors on the bracket.
d. Install the No.2 instrument lower panel.
16. CONNECT CONNECTORS, CABLE, CLAMPS AND HOSES
a. Connect the noise filter connector on the LH fender apron.
b. Connect the generator connector and wire.
c. Connect the starter connector and wire.
d. Connect the 2 ground strap connectors to the RH fender apron
e. Connect the strap connector to the LH fender apron with the bolt.
f. Connect the ground cable to the battery body bracket.
g. Connect the engine wire protector clamp to the battery body bracket.
h. Connect the engine wire clamp to the bracket on the RH fender apron.
i. Connect the brake booster vacuum hose to the throttle body.
j. Connect the engine coolant reservoir hose to the water outlet.
k. Connect the heater hose to the intake manifold.
l. Connect the heater hose to the water inlet housing.
m. Connect the fuel inlet hose to the fuel filter.

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

n. Connect the EVAP hose assembly to the pipe on the emission control valve set.
o. Connect the 2 vacuum hoses to the vacuum tank for the ACIS.
17. INSTALL FRONT EXHAUST PIPE





a. Temporarily install 3 new gaskets and the front exhaust pipe with the 2 bolts, 2 compression springs and 4 nuts.
b. Tighten the 4 nuts holding the exhaust manifolds to the front exhaust pipe.
Torque: 62 Nm (630 kgf-cm, 46 ft. lbs.)
c. Tighten the 2 bolts and 2 compression springs holding the front exhaust pipe to the center exhaust pipe.
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)
d. Install the support stay with the 2 bolts.
Torque: 33 Nm (330 kgf-cm, 24 ft. lbs.)
18. INSTALL RADIATOR
19. INSTALL CRUISE CONTROL ACTUATOR
20. INSTALL AIR CLEANER CAP ASSEMBLY AND AIR CLEANER CASE
21. CONNECT ACCELERATOR CABLE
22. INSTALL V-BANK COVER
a. Using 5 mm hexagon wrench, install the V-bank cover with the 3 cap nuts.
b. Press down the V-bank cover fastener.
23. INSTALL ENGINE FENDER APRON SEALS
24. INSTALL BATTERY TRAY AND BATTERY
25. INSTALL HOOD
26. FILL ENGINE WITH OIL
27. FILL WITH ENGINE COOLANT
28. START ENGINE AND CHECK FOR LEAKS
29. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
30. RECHECK ENGINE COOLANT AND OIL LEVELS