Engine: Service and Repair

ENGINE UNIT















REMOVAL
1. REMOVE HOOD
2. REMOVE OIL PAN PROTECTOR
3. REMOVE ENGINE UNDER COVER
4. REMOVE LOWER FRONT SUSPENSION MEMBER PROTECTOR
5. REMOVE ENGINE MOUNT MEMBER BRACKET PLATE
6. DRAIN ENGINE COOLANT
7. DRAIN ENGINE OIL
8. REMOVE V-BANK COVER
9. REMOVE BATTERY CLAMP COVER
10. REMOVE AIR CLEANER INLET
11. REMOVE AIR CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY
12. REMOVE BATTERY
13. REMOVE DRIVE BELT, FAN FLUID COUPLING AND FAN PULLEY
14. DISCONNECT ACCELERATOR CABLE TO THROTTLE BODY
15. REMOVE RADIATOR ASSEMBLY
16. REMOVE V-BANK COVER BRACKETS FROM ENGINE HANGERS
17. DISCONNECT CONNECTORS, WIRE, STRAPS, CLAMPS AND HOSES
a. Disconnect the engine oil level sensor connector.
b. Disconnect the generator connector.
c. Disconnect the generator wire.
d. Disconnect the engine wire clamp from the bracket on generator.
e. Disconnect the ground strap from the RH engine mounting bracket.
f. Disconnect the ground strap from under of the LH fender apron.
g. Disconnect the engine wire clamp from the cowl panel.
h. Disconnect the radiator reservoir hose from the water bypass pipe.
i. Disconnect the brake booster vacuum hose from the intake manifold.
j. Disconnect the heater hose from the heater water valve.
k. Disconnect the heater hose from the water bypass pipe.
l. Disconnect the fuel inlet hose from the fuel inlet pipe.
m. Disconnect the PS air hose from the intake manifold.
n. Disconnect the 2 EVAP hoses from the pipes (from charcoal canister).
o. Disconnect the oil pressure switch connector.





18. DISCONNECT ENGINE WIRE FROM CABIN
a. Remove the under cover.
b. Remove the glove compartment.
c. Disconnect the 3 ECU connectors.
d. Disconnect the cowl wire connector from the connector on the bracket.
e. Disconnect the engine wire clamp from the bracket.
f. Disconnect the grommet from the cowl panel, and pull out the engine wire.

NOTICE: Be careful not to damage the engine wire.

19. DISCONNECT PS OIL COOLER PIPE FROM OIL PAN





20. DISCONNECT HEATED OXYGEN SENSORS FROM FRONT EXHAUST PIPE
a. Disconnect the 2 wire grommets from the floor panel.
b. Disconnect the 2 oxygen sensors from the exhaust pipe.





21. REMOVE FRONT EXHAUST PIPE
a. Loosen the clamp bolt holding the front exhaust pipe to the center exhaust pipe.
b. Remove the 4 bolts and 4 nuts holding the front exhaust pipe to the TWC.
c. Remove the front exhaust pipe and 3 gaskets.
d. Remove the 2 bolts and pipe support bracket.
22. REMOVE TWC
Remove the 3 nuts, TWC and gasket. Remove the 2 TWC.





23. REMOVE CENTER EXHAUST PIPE
a. Loosen the 2 clamp bolts, and disconnect the center exhaust pipe from the tailpipes.
b. Disconnect the exhaust pipe from the 2 rings on the body brackets, and remove the center exhaust pipe and 2 gaskets.
24. REMOVE HEAT INSULATOR FOR REAR SIDE OF FRONT EXHAUST PIPE
25. REMOVE FRONT AND REAR CENTER FLOOR CROSSMEMBER BRACES
26. REMOVE PROPELLER SHAFT





27. DISCONNECT A/C COMPRESSOR FROM ENGINE
a. Disconnect the A/C compressor connector.
b. Disconnect the wire clamp from the wire bracket on the A/C compressor.
c. Remove the bolt, and disconnect the ground cable from the A/C compressor stay.
d. Remove the bolt, nut and A/C compressor stay.
e. Remove the bolt, and disconnect the wire bracket from the A/C compressor.
f. Remove the bolt, and disconnect the A/C compressor from the engine.
28. REMOVE ABS ACTUATOR





29. REMOVE PS PUMP AND OIL RESERVOIR
a. Remove the 2 bolts, nut and PS pump from the engine.
b. Remove the 3 bolts and PS oil reservoir from the RH fender apron.
30. REMOVE HEAT INSULATORS FOR FRONT SIDE OF FRONT EXHAUST PIPE
31. REMOVE ENGINE AND TRANSMISSION ASSEMBLY FROM VEHICLE





a. Remove the 2 nuts, and disconnect the heater water valve from the cowl panel.
b. Attach the engine chain hoist to the engine hangers.
c. Remove the 2 nuts holding the engine mounting insulators to the front suspension crossmember.





d. Remove the nut, and disconnect the transmission control rod from the shift lever.
e. Remove the 4 bolts, 4 nuts and rear engine mounting member.





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

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

NOTICE: Be careful not hit the PS gear housing and PNP switch.

g. Place the engine and transmission assembly onto the stand.
32. DISCONNECT ENGINE WIRE FROM TRANSMISSION
a. Disconnect the VSV connector.
b. Disconnect the PNP switch connector.
c. Disconnect the solenoid connector.
d. Disconnect the direct clutch speed sensor connector.
e. Disconnect the 4 engine wire clamps from the bracket.





33. REMOVE OIL DIPSTICK GUIDE AND DIPSTICK FOR TRANSMISSION
a. Remove the bolt.
b. Pull out the dipstick guide and dipstick from the port of transmission.
c. Remove the O-ring from the dipstick guide.
34. REMOVE OIL COOLER PIPES FOR TRANSMISSION





35. REMOVE TORQUE CONVERTER CLUTCH BOLTS
a. Remove the 2 bolts and flywheel housing under cover.
b. Turn the crankshaft pulley bolt to gain access to each bolt.
c. Hold the crankshaft pulley bolt with a wrench, and remove the 6 bolts.





36. REMOVE TRANSMISSION
a. Remove the 10 bolts and engine wire bracket.
b. Remove the transmission together with the torque converter clutch from the engine.





37. REMOVE DRIVE PLATE
Remove the 8 bolts, front spacer, drive plate and rear spacer.

INSTALLATION
1. INSTALL DRIVE PLATE





a. Apply adhesive to 2 or 3 threads of the mounting bolt end.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent





b. Install the front spacer, drive plate and rear plate on the crankshaft.
c. Install and uniformly tighten the mounting bolts in several passes, in the sequence shown.
Torque: 83 Nm (850 kgf-cm, 61 ft. lbs.)





2. INSTALL TRANSMISSION TO ENGINE
a. Attach the transmission to the engine.
b. Install the engine wire bracket and 10 bolts.
Torque:
14 mm head: 37 Nm (380 kgf-cm, 27 ft. lbs.)
17 mm head: 72 Nm (730 kgf-cm, 53 ft. lbs.)
3. INSTALL TORQUE CONVERTER CLUTCH BOLTS
a. Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent





b. Hold the crankshaft pulley bolt with a wrench, and install the 6 bolts evenly.
Torque: 41 Nm (420 kgf-cm, 30 ft. lbs.)

HINT: First install the dark green colored bolt, install the other bolts.

c. Install the flywheel housing under cover with the 2 bolts.
Torque: 18.5 Nm (185 kgf-cm, 14 ft. lbs.)
4. INSTALL OIL COOLER PIPE FOR TRANSMISSION





5. INSTALL OIL DIPSTICK GUIDE AND DIPSTICK FOR TRANSMISSION
a. Install a new O-ring to the dipstick guide.
b. Apply soapy water 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. CONNECT ENGINE WIRE TO TRANSMISSION
a. Connect the VSV connector.
b. Connect the PNP switch connector.
c. Connect the solenoid connector.
d. Connect the direct clutch.
e. Connect the 4 wire clamps to bracket.





7. INSTALL ENGINE AND TRANSMISSION ASSEMBLY IN VEHICLE
a. Attach the engine chain hoist to the engine hangers.
b. Slowly lower the engine and transmission assembly into the engine compartment.

NOTICE: Be careful not to hit the PS gear housing and PNP switch.

c. Insert the stud bolts of the front engine mounting brackets into the stud bolt holes of the front suspension crossmember.
d. Keep the engine level.





e. Install the rear engine mounting member with the 4 bolts and 4 nuts.
Torque:
Bolt: 25 Nm (250 kgf-cm, 19 ft. lbs.)
Nut: 13.5 Nm (135 kgf-cm, 10 ft. lbs.)

NOTICE: Be careful of installation direction.





f. Connect the transmission control rod to the shift lever with the nut.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
g. Install the 2 nuts holding the engine mounting brackets to the front suspension crossmember.
Torque: 70 Nm (700 kgf-cm, 52 ft. lbs.)
h. Remove the engine chain hoist.
i. Install the heater water valve with the 2 nuts.
8. INSTALL HEAT INSULATORS FOR FRONT SIDE OF FRONT EXHAUST PIPE





9. INSTALL A/C COMPRESSOR
a. Install the A/C compressor, compressor stay and wire bracket with the 3 bolts and nut.
Torque:
Bolt: 49 Nm (500 kgf-cm, 36 ft. lbs.)
Nut: 29 Nm (300 kgf-cm, 22 ft. lbs.)
b. Connect the ground cable to the compressor stay with the bolt.
c. Install the wire clamp to the bracket on the A/C compressor.
d. Connect the A/C compressor connector.





10. INSTALL PS PUMP AND OIL RESERVOIR
a. Install the PS pump with the 2 bolts and nut. Alternately tighten the bolts and nut.
Torque:
Bolt: 39 Nm (400 kgf-cm, 29 ft. lbs.)
Nut: 43 Nm (440 kgf-cm, 32 ft. lbs.)
b. Install the PS oil reservoir with the 3 bolts.
11. INSTALL ABS ACTUATOR
12. INSTALL PROPELLER SHAFT
13. INSTALL FRONT CENTER FLOOR CROSSMEMBER BRACE
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
14. INSTALL HEAT INSULATOR FOR REAR SIDE OF FRONT EXHAUST PIPE





15. INSTALL CENTER EXHAUST PIPE
a. Install 2 new gaskets.
b. Install the center exhaust pipe to the rings on the body brackets.
c. Connect the center exhaust pipe to the tailpipes.





16. INSTALL TWC
Install a new gasket and the TWC with 3 new nuts. Install the 2 TWC.
Torque: 61.8 Nm (630 kgf-cm, 46 ft. lbs.)





17. INSTALL FRONT EXHAUST PIPE
a. Temporarily install the pipe support bracket with the 2 bolts.
b. Install 2 new gaskets to the rear end of the TWC.
c. Install a new gasket to the rear of the front exhaust pipe.
d. Temporarily connect the front exhaust pipe to the center exhaust pipe.
e. Install the front exhaust pipe to the TWC and pipe support bracket with 4 new nuts and the 4 bolts.
Torque: 43.1 Nm (440 kgf-cm, 32 ft. lbs.)
f. Tighten the clamp bolt holding the front exhaust pipe to the center exhaust pipe.
g. Tighten the 4 bolts holding the pipe support bracket to the transmission.
Torque: 43.1 Nm (440 kgf-cm, 32 ft. lbs.)





18. INSTALL HEATED OXYGEN SENSORS
Install the 2 oxygen sensors to the front exhaust pipe.
Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.)

HINT:
- Before installing the oxygen sensor, twist the sensor wire counterclockwise 3 and 1/2 turns.
- After installing the oxygen sensor, check that the sensor wire is not twisted. If it is twisted, remove the oxygen sensor and reinstall it.
19. INSTALL PS OIL COOLER PIPE





20. CONNECT ENGINE WIRE TO CABIN
a. Push in the engine wire through the cowl panel. Install the grommet.
b. Connect the 3 ECM connectors.
c. Connect the cowl wire connector to the connector on the bracket.
d. Connect the engine wire clamp to the bracket.
e. Install the glove compartment.
f. Install the under cover.
21. CONNECT CONNECTORS, WIRE, STRAPS, CLAMPS AND HOSES
a. Connect the engine oil level sensor connector.
b. Connect the generator connector.
c. Connect the generator wire.
d. Connect the engine wire clamp to the bracket on the generator.
e. Connect the ground strap to the RH engine mounting bracket.
f. Connect the ground strap to under of the LH fender apron.
g. Connect the engine wire clamp to the bracket on the cowl panel.
h. Connect the radiator reservoir hose to the water bypass pipe.
i. Connect the brake booster vacuum hose to the intake manifold.
j. Connect the heater hose to the heater water valve.
k. Connect the heater hose to the water bypass pipe.
l. Connect the fuel inlet hose to the fuel inlet pipe.
m. Connect the PS air hose to the intake manifold.
n. Connect the 2 EVAP hoses to the pipes (from the charcoal canister).
o. Connect the oil pressure switch connector.
22. INSTALL V-BANK COVER BRACKETS TO ENGINE HANGERS
23. INSTALL RADIATOR ASSEMBLY
24. INSTALL BATTERY
25. CONNECT ACCELERATOR CABLES TO THROTTLE BODY
26. INSTALL FAN PULLEY, FAN, FLUID COUPLING AND DRIVE BELT
27. INSTALL AIR CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY
28. INSTALL AIR CLEANER INLET
29. INSTALL BATTERY CLAMP COVER
30. FILL WITH ENGINE COOLANT
31. FILL WITH ENGINE OIL
32. START ENGINE AND CHECK FOR LEAKS
33. INSTALL ENGINE MOUNT MEMBER BRACKET PLATE
34. INSTALL LOWER FRONT SUSPENSION MEMBER PROTECTOR
35. INSTALL V-BANK COVER
36. INSTALL ENGINE UNDER COVER
37. INSTALL OIL PAN PROTECTOR
38. INSTALL HOOD
39. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
40. RECHECK ENGINE COOLANT AND OIL LEVELS