Engine: Service and Repair

REMOVAL
1. REMOVE HOOD

NOTICE: Be careful not to damage the body or glass with the hood end.

2. REMOVE ENGINE UNDER COVER
3. DRAIN ENGINE COOLANT
4. DRAIN ENGINE OIL
5. DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY
6. REMOVE AIR CLEANER, MAF METER AND INTAKE AIR CONNECTOR PIPE ASSEMBLY
a. Disconnect the MAF meter connector.
b. Disconnect these hoses:
- PS air hose from No.4 timing belt cover
- PCV hose from No.2 cylinder head cover
- EVAP hose from air cleaner
c. Loosen the hose clamp bolt holding the intake air connector pipe to the throttle body.
d. Remove the 4 bolts, the air cleaner, MAF meter and intake air connector pipe assembly.
7. REMOVE RADIATOR ASSEMBLY
8. REMOVE DRIVE BELT, FAN, FLUID COUPLING ASSEMBLY AND WATER PUMP PULLEY
9. DISCONNECT BRAKE BOOSTER VACUUM HOSE FROM UNION
10. DISCONNECT EVAP HOSE FROM VSV FOR EVAP
11. DISCONNECT PS PUMP WITHOUT DISCONNECTING HOSES





a. Disconnect these hoses: PS air hose from No.4 timing belt cover PS air hose from air intake chamber
b. Remove the 2 bolts and pump rear stay.





c. Remove the bolt and plate washer from the pump front bracket.
d. Remove the 2 bolts, and disconnect the PS pump assembly from the engine.

HINT: Put aside the vane pump, and suspend it securely.





12. DISCONNECT A/C COMPRESSOR WITHOUT DISCONNECTING HOSES
a. Disconnect the compressor connector.
b. Remove the 2 bolts and nut.
c. Using a torx socket (E10), remove the stud bolt, and disconnect the compressor from the engine.

HINT: Put aside the compressor, and suspend it.

13. DISCONNECT CONNECTORS, WIRES AND HOSES
a. Disconnect the engine wire from the 2 wire clamps.





b. Disconnect these connectors:
1) 2 connectors from engine room main wire
2) Igniter connector
3) Theft deterrent horn connector
4) Noise filter connector





c. Using a 6 mm hexagon wrench, remove the bolt and connector bracket.
d. Disconnect the wire clamp and PPS solenoid valve connector.
e. Disconnect the PS pressure switch connector.
f. Remove the bolt, and disconnect the ground cable from the cylinder block.
g. Remove the cap and nut, and disconnect the generator wire.
h. Disconnect the engine wire from the wire clamp.





i. Disconnect these hoses:
1) Vacuum hose (from VSV for heater water valve) from check valve
2) Heater hose from heater water valve
3) Heater hose from water bypass pipe
j. Disconnect the VSV connector.





k. Disconnect the ground strap from the bracket on the body.
l. Remove the bolt holding the engine wire protector from the body.





m. Remove the bolt holding the engine wire protector to the heater valve bracket.
n. Remove the 2 bolts holding the engine wire clamp to body.
14. DISCONNECT ENGINE WIRE FROM CABIN





a. Remove the 2 clips, and pull out the instrument panel under cover.





b. Remove the 4 mounting screws.
c. Disconnect the connectors, and remove the lower instrument panel, finish panel and glove compartment door assembly.





d. Pull out the scuff plate.





e. Take out the front side of the floor carpet.
f. Remove the 2 nuts and ECM protector.





g. Disconnect these connectors:
1) 6 connectors from ECM
2) 4 connectors from connector cassette
3) Connector from A/C control assembly
h. Pull out the engine wire from the cabin.





15. DISCONNECT FUEL INLET HOSE AND STARTER WIRE
a. Remove the union bolt and 2 gaskets, disconnect the fuel inlet hose, and suspend the hose union end upward.

NOTICE:
- Put a suitable container or shop towel under the fuel pipe support.
- Slowly loosen the union bolt.

b. Remove the nut, and disconnect the starter wire.
c. Disconnect the starter wire from the clamp bracket.





16. DISCONNECT PS PRESSURE FEED HOSE FROM ENGINE
Remove the 2 clamp bolts, and disconnect the pressure feed hose.
17. REMOVE EXHAUST MANIFOLD
18. REMOVE EXHAUST PIPE HEAT INSULATOR
Remove the 4 nuts and heat insulator.





19. REMOVE INTERMEDIATE SHAFT
a. Place the matchmarks on the both flanges.
b. Remove the 2 center support bearing set bolts and the adjusting washers.

HINT: Some vehicles are not equipped with an adjusting washer.

c. Remove the 4 bolts, washers, nuts and intermediate shaft.
d. Insert SST in transmission to prevent oil leakage.
SST 09325-40010





20. DISCONNECT TRANSMISSION CONTROL ROD
Remove the nut, and disconnect the control rod from the shift lever.
21. PLACE JACK UNDER TRANSMISSION

NOTICE: Be sure to put a wooden block between the jack and the transmission oil pan to prevent damage.





22. REMOVE REAR SUPPORT MEMBER
a. Remove the 4 nuts holding the member to the engine rear mounting insulator.
b. Remove the 4 bolts and rear support member.
23. REMOVE ENGINE AND TRANSMISSION ASSEMBLY FROM VEHICLE





a. Install a No.1 engine hanger in the correct direction.
Part No.: No.1 engine hanger 12281-46050, Bolt 90105-10345
Torque: 40 Nm (400 kgf-cm, 30 ft. lbs.)
b. Attach the sling device to the engine hangers.

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





c. Remove the 2 nuts holding the engine front mounting insulators to the front suspension crossmember.





d. Lift the engine out of the vehicle slowly and carefully.

NOTICE: Remove the engine and transmission assembly carefully without damaging the A/C compressor or PS solenoid valve

e. Make sure the engine is clear of all wiring, hoses and cables.
f. Place the engine and transmission assembly onto the stand.
24. REMOVE OIL DIPSTICK AND GUIDE FOR A/T
a. Remove the bolt.
b. Pull out the dipstick guide together with the dipstick.
c. Remove the O-ring from the dipstick guide.
25. REMOVE OIL COOLER PIPES
26. DISCONNECT ENGINE WIRE FROM TRANSMISSION
27. REMOVE STARTER
28. SEPARATE ENGINE AND TRANSMISSION


INSTALLATION
1. ASSEMBLY ENGINE AND TRANSMISSION
2. INSTALL STARTER
3. CONNECT ENGINE WIRE TO TRANSMISSION
4. INSTALL OIL COOLER PIPES
5. INSTALL OIL DIPSTICK GUIDE AND DIPSTICK FOR A/T
a. Install a new O-ring to the dipstick guide.
b. Apply new oil to the O-ring.
c. Connect the dipstick guide end to the dipstick tube of the oil pan.
d. Install the dipstick guide with the bolt.
e. Install the dipstick.
6. INSTALL ENGINE AND TRANSMISSION ASSEMBLY IN VEHICLE





a. Attach the engine hoist chain to the engine hangers.





b. Lower the engine and transmission assembly into the engine compartment.

NOTICE: Install the engine and transmission assembly carefully without damaging the A/C compressor and PS, solenoid valve.

c. Insert the stud bolts of the front engine mounting insulators into the stud bolt holes of the front suspension crossmember.
d. Temporarily install the 2 nuts holding the engine front mounting insulators to the front suspension crossmember.
e. Keep the engine level with a jack.
f. Remove the hoist chain.
g. Remove the bolt and No.1 engine Hanger.





h. Temporarily install the support member to the engine rear mounting insulator with the 4 nuts.
i. Install the 4 bolts holding the support member to the body.
Torque: 25 Nm (260 kgf-cm, 19 ft. lbs.)
Tighten the 4 nuts holding the support member to the engine rear mounting insulator.
Torque: 13 Nm (135 kgf-cm, 10 ft. lbs.)





k. Tighten the 2 nuts holding the engine front mounting insulators to the front suspension crossmember.
Torque: 59 Nm (600 kgf-cm, 43 ft. lbs.)





7. CONNECT TRANSMISSION CONTROL ROD
a. Shift the shift lever to N position.
b. Fully turn the control shaft lever back and return 2 notches. It is now in neutral position.
c. Connect the control rod to the shift lever with the nut.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
8. INSTALL INTERMEDIATE SHAFT
a. Remove the SST from the yoke of the transmission.
SST 09325-40010
b. Insert the yoke into the transmission.





c. Align the matchmarks on the flanges, and connect the propeller shaft with the 4 bolts, washers and nuts.
d. Torque the bolts and nuts.
Torque: 74 Nm (750 kgf-cm, 54 ft. lbs.)
e. Temporarily install the center support bearing set bolts with the adjusting washers.

HINT: Use the adjusting washers which were removed.

f. Torque the bolts, and inspect the joint angle.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
9. INSTALL EXHAUST PIPE HEAT INSULATOR
Install the heat insulator with the 4 nuts.
10. INSTALL EXHAUST MANIFOLD





11. INSTALL STARTER WIRE AND FUEL INLET HOSE
a. Install the ground strap to the transmission.
b. Install the starter wire with the nut.
c. Install the starter wire with the wire clamp.
d. Install the fuel inlet hose with 2 new gaskets and the union bolt.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)
12. INSTALL PS PRESSURE FEED HOSE
Install the pressure feed hose with the 2 clamp bolts.





13. CONNECT ENGINE WIRE TO CABIN
a. Push in the engine wire through the cowl panel.
b. Connect these connectors:
1) 6 connectors to ECM
2) 4 connectors to connector cassette
3) Connector to A/C control assembly
c. Install the ECM protector with the 2 nuts.
d. Install the floor carpet.
e. Install the scuff plate.
f. Connect the connectors.
g. Install the lower instrument panel finish panel and glove compartment door assembly with the 4 screws.
h. Install the instrument panel under cover with the 2 clips.
14. CONNECT CONNECTOR, WIRES AND HOSES
a. Install the engine wire clamp with the 2 bolts.
b. Install the bolt holding the engine wire protector to the water valve bracket.
c. Install the bolt holding the engine wire protector to the body.
d. Install the ground strap to the bracket on the body.
e. Connect the VSV connector.
f. Connect these hoses:
- Heater hose to water bypass pipe
- Heater hose to heater water valve
- Vacuum hose (from VSV for heater water valve) to check valve
g. Install the generator wire with the nut and cap.
h. Connect the engine wire to the wire clamp.
i. Connect the PS pressure switch connector.
j. Install the ground cable on the cylinder block.
k. Connect the PPS solenoid valve connector and wire clamp.
l. Using a 6 mm hexagon wrench, install the connector bracket with the bolt.
m. Connect these connectors:
- 2 connectors to engine room main wire
- Igniter connector
- Theft deterrent horn connector
- Noise filter connector
n. Install the engine wire with the 2 wire clamps.
15. INSTALL A/C COMPRESSOR
a. Using a torx socket (E10), install the stud bolt and compressor.
Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)
b. Connect the compressor connector.
c. Install the compressor with the nut and 2 bolts.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)





16. INSTALL PS PUMP
a. Install the PS pump assembly with the 3 bolts and plate washer.
Torque:
58 Nm (590 kgf-cm, 43 ft. lbs.) for A
52 Nm (530 kgf-cm, 38 ft. lbs.) for B
b. Install the pump rear stay with the 2 bolts.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
c. Connect these hoses:
- PS air hose to No.4 timing belt cover
- PS air hose to air intake chamber
17. CONNECT EVAP HOSE TO VSV FOR EVAP
18. CONNECT BRAKE BOOSTER VACUUM HOSE TO UNION
19. INSTALL WATER PUMP PULLEY, FAN, FLUID COUPLING ASSEMBLY AND DRIVE BELT
20. INSTALL RADIATOR ASSEMBLY
21. INSTALL AIR CLEANER, MAF METER AND INTAKE AIR CONNECTOR PIPE ASSEMBLY
a. Connect the air cleaner case to the air duct.
b. Connect the intake air connector pipe to the throttle body.
c. Install the air cleaner, MAF meter and intake air connect9ift pipe assembly with the 4 bolts.
d. Tighten the hose clamp bolt holding the intake air connector pipe to the throttle body.
e. Connect these hoses: PS air hose to No.4 timing belt cover PCV hose to No.2 cylinder head cover EVAP hose to air cleaner
f. Inspect the MAF meter connector.
22. CONNECT ACCELERATOR CABLE TO THROTTLE BODY
23. FILL WITH ENGINE OIL
24. FILL WITH ENGINE COOLANT
25. START ENGINE AND CHECK FOR LEAKS
26. CHECK AUTOMATIC TRANSMISSION FLUID LEVEL
27. INSTALL ENGINE UNDER COVER
28. INSTALL HOOD
29. ROAD TEST
Check for abnormal noise, shock slippage, correct shift points and smooth operation.
30. RECHECK ENGINE COOLANT AND ENGINE OIL LEVELS