Engine: Service and Repair

REMOVAL
1. REMOVE HOOD
2. REMOVE ENGINE UNDER COVERS
3. REMOVE V-BANK COVER AND BATTERY
4. DRAIN ENGINE COOLANT
5. DRAIN ENGINE OIL
6. REMOVE DRIVE BELT
7. DISCONNECT ACCELERATOR CABLE





8. REMOVE AIR CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY
a) Disconnect the MAP meter connector.
b) Disconnect the PS air hose.
c) Disconnect the PCV hose.
d) Disconnect the EVAP hose.
e) Disconnect the intake air connector from the throttle body.
f) Remove the 6 bolts and air cleaner and intake air connector assembly.
9. REMOVE COOLING FAN RESERVOIR AND RADIATOR ASSEMBLY





10. DISCONNECT ENGINE WIRE CONNECTORS
a) Disconnect the 2 engine wire connectors.
b) Disconnect the engine wire from the wire clamp.
c) Disconnect the engine wire from the body.
11. DISCONNECT THEFT DETERRENT HORN CONNECTOR
12. DISCONNECT GROUND CABLE FROM BODY





13. DISCONNECT POWER STEERING (PS) SOLENOID VALVE CONNECTOR





14. DISCONNECT POWER STEERING (PS) TUBES
Remove the bolt, and disconnect the PS tubes.
15. DISCONNECT POWER STEERING (PS) RESERVOIR TANK AND BRACKET FROM BODY
Remove the 3 bolts, and disconnect the reservoir tank and bracket assembly.





16. DISCONNECT POWER STEERING (PS) PUMP FROM ENGINE
Remove the nut and 2 bolts, and disconnect the PS pump from the engine.

HINT: Put aside the PS pump, and suspend it.

17. REMOVE GENERATOR
18. DISCONNECT AIR CONDITIONING (A/C) COMPRESSOR FROM ENGINE





a) Disconnect the A/C compressor connector.
b) Remove the nut, and disconnect the ground cable from the A/C compressor stay.
c) Remove the bolt and A/C compressor stay.





d) Disconnect the wire clamp from the A/C compressor.
e) Remove the 2 bolts, and disconnect the A/C compressor from the engine.

HINT: Put aside the A/C compressor, and suspend it.

19. DISCONNECT HOSES AND GROUND STRAP





a) Disconnect the heater water hose from the water bypass pipe.
b) Disconnect the heater water hose from the heater water valve.
c) Disconnect the brake booster vacuum hose.
d) Disconnect the vacuum hose (from the VSV for heater water valve).
e) Disconnect the PS air hose.
f) Disconnect the ground strap from the bracket on body.





g) Disconnect the EVAP hose from the VSV for EVAP.
h) Disconnect the fuel hose.
20. DISCONNECT ENGINE WIRE FROM CABIN





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





b) Remove the 4 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) Remove the 2 nuts, and disconnect the ECM from the floor panel.





h) Disconnect the 6 connectors from the ECM.
i) Disconnect the 4 connectors from the connector cassette.
j) Disconnect the connector from the A/C control assembly.





k) Remove the bolt holding the engine wire clamp to the heater water valve bracket.
l) Remove the 2 bolts holding the engine wire clamp to the body.
m) Disconnect the VSV connector for heater water valve.





n) Pull out the engine wire from the cabin.

NOTICE: Be careful not to damage the engine wire.





21. DISCONNECT HEATED OXYGEN SENSORS (BANK1, 2 SENSOR2) FROM FRONT EXHAUST PIPE
a) Disconnect the 2 wire grommets from the floor panel.
b) Disconnect the 2 oxygen sensors from the exhaust pipe.





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





23. REMOVE TWC
Using a 14 mm deep socket wrench, remove the 3 nuts, TWC and gasket. Remove the 2 TWCs.





24. REMOVE TAILPIPE
a) Remove the 4 nuts holding the tailpipes to the center exhaust pipe.
b) Disconnect the hook from the ring on tailpipe bracket, and remove the tailpipe and gasket. Remove the 2 tailpipes.





25. REMOVE CENTER EXHAUST PIPE
Disconnect the 2 hooks of the exhaust pipe from the rings on exhaust pipe brackets, and remove the exhaust pipe.





26. REMOVE HEAT INSULATOR FOR FRONT EXHAUST PIPE
Remove the 4 nuts and heat insulator.
27. REMOVE CENTER FLOOR CROSSMEMBER BRACE
Remove the 4 bolts and crossmember brace.





28. DISCONNECT TRANSMISSION CONTROL ROD FROM SHIFT LEVER
Remove the nut, and disconnect the control rod from the shift lever.
29. REMOVE PROPELLER SHAFT
30. REMOVE ENGINE AND TRANSMISSION ASSEMBLY FROM VEHICLE





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





b) Remove the 2 nuts holding the engine mounting insulators to the front suspension crossmember.
c) Remove the 4 bolts, 4 nuts and rear engine mounting member. Disconnect the ground strap.





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

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

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

e) Place the engine and transmission assembly onto the stand.





31. 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.
32. REMOVE OIL COOLER PIPES FOR TRANSMISSION
a) Remove the 2 bolts.
b) Loosen the 2 union nuts, and remove the oil cooler pipes.
33. REMOVE TRANSMISSION





34. 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 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 8 bolts in several passes, in the sequence shown.
Torque: 98 Nm (1,000 kgf-cm, 72 ft. lbs.)
2. INSTALL TRANSMISSION TO ENGINE
3. INSTALL OIL COOLER PIPE FOR TRANSMISSION
a) Temporarily install the oil cooler pipe with the 2 pipe brackets and 2 bolts.
b) Connect the 2 oil cooler pipes to the unions on the transmission.
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)
c) Tighten the 2 pipe clamp bolts.





4. 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.
5. 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 Nm (135 kgf-cm, 10 ft. lbs.)





f) Install the 2 nuts holding the engine mounting brackets to the front suspension crossmember.
Torque: 59 Nm (600 kgf-cm, 43 ft. lbs.)
6. CONNECT TRANSMISSION CONTROL ROD TO SHIFT LEVER
Connect the control rod to the shift lever with the nut.
7. INSTALL PROPELLER SHAFT





8. INSTALL CENTER FLOOR CROSSMEMBER BRACE
Install the crossmember brace with the 4 nuts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
9. INSTALL HEAT INSULATOR FOR FRONT EXHAUST PIPE
Install the heat insulator with the 4 bolts.
10. INSTALL CENTER EXHAUST PIPE
Install the 2 hooks of the exhaust pipe to the rings on the exhaust pipe brackets.





11. INSTALL TAILPIPE
a) Install the hook of the tailpipe to the ring on the tailpipe bracket.
b) Install a new gasket and tailpipe to the center exhaust pipe with 2 bolts. Install the 2 tailpipes.
Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)
12. INSTALL TWC
Using a 14 mm deep socket wrench, install a new gasket and the TWC with 3 new nuts. Install the 2 TWC.
Torque: 62 Nm (630 kgf-cm, 46 ft. lbs.)
13. INSTALL FRONT EXHAUST PIPE
a) Temporarily install the pipe support bracket with the 4 bolts.
b) Temporarily install 3 new gaskets and the exhaust pipe with the 6 bolts and nuts.
c) Tighten the 4 bolts and nuts holding the TWC to the front exhaust pipe.
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)
d) Tighten the 2 bolts and nuts holding the front exhaust pipe to the center exhaust pipe.
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)
e) Tighten the 4 bolts holding the pipe support bracket to the transmission.
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)
14. INSTALL HEATED OXYGEN SENSORS (BANK1, 2 SENSOR2)
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.

15. CONNECT ENGINE WIRE TO CABIN
a) Push in the engine wire through the cowl panel.

NOTICE: Be careful not to damage the engine wire. Tape the engine wire.

b) install the engine wire retainer with the 2 bolts.
c) Connect the 6 connectors to ECM.
d) Connect the 4 connectors to connector cassette.
e) Connect the connector to A/C control assembly.
f) Install the ECM with the 2 nuts.
g) Install the ECM protector with the 2 nuts.
h) Install the floor carpet.
i) Install the scuff plate.
j) Connect the connectors.
k) Install the lower instrument panel finish panel and glove compartment door assembly with the 4 screws.
l) Install the instrument panel under cover with the 2 clips.
16. CONNECT HOSES AND GROUND STRAP





a) Connect the heater water hose to the water bypass pipe.
b) Connect the heater water hose to the heater water valve.
c) Connect the brake booster vacuum hose.
d) Connect the vacuum hose (from the VSV for heater water valve) to the intake manifold.
e) Connect the PS air hose.
f) Connect the ground strap to the bracket on body.





g) Connect the EVAP hose to the VSV for EVAP.
Using SST, connect the fuel hose.
SST 09278-54012
Torque: 30 Nm (310 kgf-cm, 22 ft. lbs.)

HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 inch).

17. INSTALL AIR CONDITIONING (A/C) COMPRESSOR
a) Install the A/C compressor with the 2 bolts.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
b) Connect the wire clamp to the A/C compressor.
c) Install the A/C compressor stay with the bolt.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)
d) Connect the ground cable to the A/C compressor stay with the nut.
e) Connect the A/C compressor connector.
18. INSTALL GENERATOR





19. INSTALL POWER STEERING (PS) PUMP TO ENGINE
a) Install the PS pump with the nut and 2 bolts. 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.)
20. INSTALL POWER STEERING (PS) RESERVOIR TANK AND BRACKET TO BODY
21. INSTALL POWER STEERING (PS) TUBES TO SUSPENSION CROSSMEMBER
22. INSTALL POWER STEERING (PS) SOLENOID VALVE CONNECTOR
23. INSTALL GROUND CABLE TO BODY
24. CONNECT THEFT DETERRENT HORN CONNECTOR
25. CONNECT ENGINE WIRE CONNECTORS
26. INSTALL RADIATOR ASSEMBLY AND RESERVOIR TANK
27. INSTALL AIR CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY
28. CONNECT ACCELERATOR CABLE
29. INSTALL DRIVE BELT
30. FILL WITH ENGINE COOLANT
31. FILL WITH ENGINE OIL
32. INSTALL V-BANK COVER AND BATTERY
33. START ENGINE AND CHECK FOR LEAKS
34. CHECK TRANSMISSION FLUID LEVEL
35. DO ENGINE ADJUSTMENT
36. INSTALL ENGINE UNDER COVERS
37. INSTALL HOOD
38. DO ROAD TEST
Check for abnormal noises, shock slippage, correct shift points and smooth operation.
39. RECHECK ENGINE COOLANT AND OIL LEVELS