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. REMOVE ENGINE COVER
Remove the 4 nuts and engine cover.
6. REMOVE AIR CLEANER INLET
7. REMOVE AIR CLEANER, MAF METER AND INTAKE AIR RESONATOR ASSEMBLY
a. Disconnect the MAF meter connector.
b. Disconnect the engine wire clamp from the air cleaner case.
c. Disconnect the EVAP hose from the air cleaner case.
d. Disconnect the PCV hose from the No.2 cylinder head cover.
e. Loosen the hose clamp bolt holding the intake air resonator to the throttle body.
f. Remove the 3 bolts, the air cleaner, MAF meter and intake air resonator assembly.
8. DISCONNECT ACCELERATOR CABLE FROM ENGINE
9. REMOVE RADIATOR ASSEMBLY
10. REMOVE DRIVE BELT
11. REMOVE FRONT SUSPENSION MEMBER BRACE
Remove the 6 bolts and brace.
12. DISCONNECT WIRES, CABLE, STRAP, CONNECTORS, HOSES AND CLAMPS
a. Disconnect the ground wire from the floor.
b. Disconnect the starter wire from the terminal and manifold stay.
c. Disconnect the fuel inlet hose from the fuel pipe support.
d. Disconnect the ground strap from the dash panel.
e. Disconnect the heater hose from the heater pipe.
f. Disconnect the heater hose from the water bypass pipe.
g. Disconnect the EVAP hose from the pipe (from charcoal canister).
h. Disconnect the heater oxygen sensor (bank 1 sensor 1) connector.
i. Disconnect the heater oxygen sensor (bank 1 sensor 2) connector.
j. Disconnect the generator wire.
k. Disconnect the engine wire clamp from the wire clip of generator.
l. Disconnect the ground cable from the bracket on the cylinder block.
m. Disconnect the igniter connector.
n. Disconnect the DLC1.
o. Disconnect the 2 engine wire clamps from the clamp brackets.
13. DISCONNECT ENGINE WIRE FROM ECM BOX
a. Remove the ECM hood and ECM cover.
b. Disconnect the 3 ECM connectors.
c. Disconnect the 4 wire harness connectors.
d. Disconnect the 2 junction connectors.
e. Disconnect the grommet and engine wire from the ECM box.
14. DISCONNECT PS PUMP AND A/C COMPRESSOR WITHOUT DISCONNECTING HOSES
a. Disconnect the PS air hose from the No.4 timing belt cover.
b. Disconnect the PS air hose from the air intake chamber.
c. Remove the 2 bolts and pump rear stay.
d. Remove the 3 bolts and plate washer, and disconnect the vane pump assembly from the engine. Loosen the nut.
e. Using a torx socket (E10), remove the stud bolt and nut.
f. Disconnect the PS solenoid valve connector.
g. Disconnect the A/C compressor connector.
h. Remove the 2 bolts, and disconnect the compressor from the engine.
HINT: Put aside the vane pump and compressor, and suspend it securely.
15. REMOVE PROPELLER SHAFT
16. REMOVE TRANSMISSION CONTROL ROD
Remove the 2 nuts and control rod.
17. DISCONNECT PS GEAR HOUSING
a. Check the steering wheel at the straight ahead position, and place matchmarks on the sliding yoke and intermediate shaft.
b. Remove the bait holding the sliding yoke to the steering intermediate shaft.
c. Disconnect the PS pressure switch connector and wire clamp.
d. Remove the 4 bolts, and disconnect the PS housing from the front frame.
e. Disconnect the sliding yoke from the intermediate shaft.
HINT: Suspend the PS gear housing securely.
18. REMOVE ENGINE AND TRANSMISSION ASSEMBLY FROM VEHICLE
a. Install the 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 engine chain hoist to the engine hangers.
c. Remove the 2 hole plugs.
d. Remove the 4 nuts holding the engine mounting insulators to the front suspension crossmember.
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.
g. Place the engine and transmission assembly onto the stand.
19. REMOVE OIL DIPSTICK AND GUIDE FOR A/T
a. Disconnect the engine wire clamp from the dipstick guide.
b. Remove the bolt.
c. Pull out the dipstick guide and dipstick from the dipstick tube. Remove the O-ring from the dipstick guide.
20. REMOVE EXHAUST MANIFOLD
a. Remove the case clamp.
b. Disconnect the heated oxygen sensor (bank 2 sensor 1) connector. Remove the 8 nuts, exhaust manifold and 2 gaskets.
21. REMOVE OIL COOLER PIPES FOR A/T
a. Remove the 3 bolts and pipe clamps.
b. Loosen the 2 union nuts, and remove the 2 oil cooler pipes.
22. REMOVE TORQUE CONVERTER CLUTCH BOLTS
a. Remove the hole plug.
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.
23. REMOVE 4 BOLTS HOLDING NO.1 OIL PAN TO TRANSMISSION
24. REMOVE STARTER
a. Disconnect the starter connector.
b. Remove the 2 bolts, clamp bracket and starter.
25. DISCONNECT ENGINE WIRE FROM TRANSMISSION
a. Disconnect the VSS connector.
b. Disconnect the PNP switch connector.
c. Disconnect the solenoid connector.
d. Disconnect the direct clutch speed sensor connector.
e. Disconnect the engine wire from the 3 wire clamps.
26. REMOVE TRANSMISSION FROM ENGINE
a. Remove the 5 bolts and ground wire.
b. Remove the transmission together with the torque converter clutch from the engine.
27. REMOVE DRIVE PLATE
Remove the 8 bolts, rear plate, drive plate and front spacer.
INSTALLATION
1. INSTALL DRIVE PLATE
a. Install the front spacer, drive plate and rear plate on the crankshaft.
b. Apply adhesive to 2 or 3 threads of the mounting bolt end.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
c. Install the uniformly tighten the 8 mounting bolts, in several passes.
Torque: 83 Nm (850 kgf-cm, 61 ft. lbs.)
2. INSTALL TRANSMISSION TO ENGINE
a. Check the torque converter clutch installation.
b. Attach the transmission to the engine.
c. Install the ground wire and bolts.
Torque: 72 Nm (730 kgf-cm, 53 ft. lbs.)
3. CONNECT ENGINE WIRE TO TRANSMISSION
a. Connect the VSS connector.
b. Connect the PNP switch connector.
c. Connect the solenoid connector.
d. Connect the direct clutch speed sensor connector.
e. Connect the engine wire to the 3 wire clamps.
4. INSTALL STARTER
a. Install the starter and clamp bracket with the 2 bolts.
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)
b. Connect the starter connector.
5. INSTALL 4 BOLTS HOLDING NO.1 OIL PAN TO TRANSMISSION
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)
6. 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: 48 Nm (490 kgf-cm, 35 ft. lbs.)
HINT: First install the dark green colored bolt, install the other bolts.
c. Install the hole plug.
7. INSTALL OIL COOLER PIPE FOR A/T
8. INSTALL EXHAUST MANIFOLD
a. Install 2 new gaskets to the cylinder head.
b. Using a 14 mm deep socket wrench, install the exhaust manifold with the 8 nuts. Uniformly tighten the nuts in several passes.
Torque: 40 Nm (408 kgf-cm, 30 ft. lbs.)
c. Connect the heated oxygen sensor (bank 2 sensor 1) connector.
d. Install the case clamp.
9. INSTALL OIL DIPSTICK GUIDE AND DIPSTICK FOR A/T
a. Install a new O-ring to the dipstick guide.
b. Push in the dipstick guide end to the dipstick tube of the oil pan.
c. Install the dipstick guide with the bolt.
d. Connect the engine wire clamp to the dipstick guide.
e. Install the dipstick.
10. 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.
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:
25.5 Nm (260 kgf-cm, 19 ft. lbs.) for bolts
13.5 Nm (135 kgf-cm 10 ft. lbs.) for nuts
NOTICE: Be careful of installation direction.
f. Install the 4 nuts holding the engine mounting brackets to the front suspension crossmember.
Torque: 70 Nm (714 kgf-cm, 52 ft. lbs.)
g. Install the 2 hole plugs.
h. Remove the engine chain hoist.
i. Remove the bolt and No.1 engine hanger.
11. INSTALL PS GEAR HOUSING
a. Align the matchmarks and connect the sliding yoke to the steering intermediate shaft.
b. Install the PS gear housing with the 4 bolts.
Torque: 65 Nm (660 kgf-cm, 48 ft. lbs.)
c. Install the bolt holding the sliding yoke to the steering intermediate shaft.
Torque: 35 Nm (360 kgf-cm, 26 ft. lbs.)
d. Connect the PS pressure switch and wire clamp.
12. INSTALL TRANSMISSION CONTROL ROD
Install the control rod with the 2 nuts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
If the indicator is not aligned with the correct position, carry out the following adjustment procedures.
1. Loosen the nut on the shift lever.
2. Push the control shaft lever fully rearward.
3. Return the control shaft lever 2 notches to the N position.
4. Set the shift lever to the N position.
5. While holding the shift lever lightly toward the R position side, tighten the nut.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
13. INSTALL A/C COMPRESSOR AND PS PUMP
a. Temporarily install the compressor with the 2 bolts.
b. Using a torx socket (E10), install the stud bolt.
Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)
c. Tighten the nut and 2 bolts.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)
d. Connect the compressor connector.
e. Connect the PS solenoid valve connector.
f. Install the vane pump assembly with the 3 bolts and plate washer.
Torque:
57.9 Nm (590 kgf-cm, 43 ft. lbs.) for A bolts
52 Nm (530 kgf-cm, 38 ft. lbs.) for B bolt
g. Install the pump rear stay with the 2 bolts.
Torque: 39.2 Nm (400 kgf-cm, 29 ft. lbs.)
h. Connect the PS air hose to the No.4 timing belt cover.
i. Connect the PS air hose to the air intake chamber.
14. CONNECT ENGINE WIRE TO ECM BOX
a. Install the engine wire grommet to the ECM box.
b. Connect the 3 ECM connectors.
c. Connect the 4 wire harness connectors.
d. Connect the 2 junction connectors.
e. Install the ECM cover and ECM hood.
15. CONNECT CLAMPS, WIRES, CONNECTORS, HOSES, CABLE AND STRAP
a. Connect the 2 engine wire clamps to the clamp brackets.
b. Connect the DLC1.
c. Connect the igniter connector.
d. Connect the ground cable to the bracket on the cylinder block.
e. Connect the engine wire clamp to the wire clip of the generator.
f. Connect the generator wire.
g. Connect the heated oxygen sensor (bank 1 sensor 1) connector.
h. Connect the heated oxygen sensor (bank 1 sensor 2) connector.
i. Connect the EVAP hose to the pipe (from charcoal canister).
j. Connect the heater hose to the heater pipe.
k. Connect the heater hose to the water bypass pipe.
l. Connect the ground strap to the dash panel.
m. Connect the fuel inlet hose to the fuel pipe support.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)
n. Connect the starter wire to the terminal and manifold stay.
o. Connect the ground wire to the floor.
16. INSTALL FRONT SUSPENSION MEMBER BRACE
Install the brace with the 6 bolts.
Torque: 58 Nm (590 kgf-cm, 43 ft. lbs.)
17. INSTALL DRIVE BELT
18. INSTALL RADIATOR ASSEMBLY
19. CONNECT ACCELERATOR CABLE TO ENGINE
20. INSTALL AIR CLEANER, MAP METER AND INTAKE AIR CONNECTOR PIPE ASSEMBLY
a. Connect the intake air resonator to the throttle body.
b. Install the air cleaner case with the 3 bolts.
c. Tighten the hose clamp bolt holding the intake air resonator to the throttle body.
d. Connect the MAF meter connector.
e. Connect the engine wire clamp to the air cleaner case.
f. Connect the EVAP hose to the air cleaner case.
g. Connect the PCV hose to the No.2 cylinder head cover.
21. INSTALL AIR CLEANER INLET
22. INSTALL ENGINE COVER
Install the engine cover with the 4 nuts.
23. FILL WITH ENGINE COOLANT
24. FILL WITH ENGINE OIL
25. START ENGINE AND CHECK FOR LEAKS
26. INSTALL ENGINE UNDER COVER
27. INSTALL HOOD
NOTICE: Be careful not to damage the body or glass with the hood end.
28. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
29. RECHECK ENGINE COOLANT AND OIL LEVELS