Engine: Service and Repair

ECM Cover And Connectors:

REMOVAL
1. REMOVE HOOD
2. REMOVE ENGINE UNDER COVER
3. DRAIN ENGINE COOLANT
4. DRAIN ENGINE OIL
5. REMOVE V-BANK COVER
6. REMOVE AIR CLEANER INLET
7. REMOVE AIR CLEANER ASSEMBLY
8. REMOVE INTAKE AIR CONNECTOR PIPE
9. REMOVE RADIATOR ASSEMBLY
10. REMOVE DRIVE BELT





11. REMOVE FRONT SUSPENSION MEMBER BRACE
Remove the 6 bolts and brace.
12. DISCONNECT WIRE, CABLES, HOSES AND CLAMP
- Disconnect the generator wire from generator.
- Disconnect the wire for generator wire from wire clamp on generator.
- Disconnect the ground cable from stay on generator.
- Disconnect the PS oil hose from No. 1 oil pan.
- Disconnect the 2 PS air hoses from hose clamp on No. 3 RH timing belt cover.
- Disconnect the hose clamp for PS air hose.
- Disconnect the PS air hose from upper intake manifold.
- Disconnect the starter cable from battery.
- Disconnect the ground strap from body.
- Disconnect the 2 heater hoses.
- Disconnect the fuel inlet hose (rear fuel pipe) from fuel main tube.
13. DISCONNECT ENGINE WIRE FROM ECU BOX
a. Remove these parts:
- Remove the ECM cover
- Remove the ECM hood
b. Disconnect these connectors:
- Disconnect the 3 engine ECM connectors
- Disconnect the 4 wire harness connectors
- Disconnect the 2 junction connectors
c. Disconnect the grommet and engine wire from the ECM box.
14. 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.
15. REMOVE FRONT AND CENTER EXHAUST PIPES





16. REMOVE TWC
Remove the 3 nuts, TWC and gasket. Remove the 2 TWC.
17. REMOVE CENTER FRONT FLOOR BRACE
18. REMOVE HEAT INSULATORS
19. REMOVE PROPELLER SHAFT





20. 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, nut and A/C compressor stay.
d. Remove the bolt, and disconnect the wire bracket from the A/C compressor.
e. Remove the bolt, and disconnect the A/C compressor from the engine.





21. REMOVE PS PUMP
a. Remove the 2 screws and RH engine under cover.
b. Disconnect the PS oil pressure switch connector.
c. Remove the 2 bolts and nut, and disconnect the PS pump from the engine.





22. REMOVE TRANSMISSION CONTROL ROD
Remove the 2 clips and control rod.
23. DISCONNECT PS GEAR HOUSING





a. Check the steering wheel at the straight-ahead position.
b. Remove the bolt holding the sliding yoke to the steering intermediate shaft.





c. Remove the bolt, and disconnect the 2 PS oil tubes from the front frame.
d. Remove the 4 bolts, and disconnect the PS gear housing from the front frame.
e. Disconnect the sliding yoke from the intermediate shaft.

HINT: Suspend the PS gear housing securely.

24. REMOVE ENGINE AND TRANSMISSION ASSEMBLY FROM VEHICLE





a. Remove the nut and No.1 V-bank cover bracket from the No.2 engine hanger.
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.
25. DISCONNECT ENGINE WIRE FROM TRANSMISSION
Disconnect the connectors and wire:
- Disconnect the VSV connector.
- Disconnect the PNP switch connector.
- Disconnect the solenoid connector.
- Disconnect the direct clutch speed sensor connector.
- Disconnect the engine wire from 3 wire clamps.
26. REMOVE OIL DIPSTICK GUIDE AND DIPSTICK FOR TRANSMISSION
a. Remove the bolt.
b. Pull out the dipstick guide and dipstick from the dipstick tube of transmission.
c. Remove the O-ring from the dipstick guide.
27. REMOVE OIL COOLER PIPES FOR TRANSMISSION
a. Disconnect the oil level sensor connector.
b. Remove the 3 bolts and 3 stays.
c. Loosen the 2 union nuts, and remove the 2 oil cooler pipes.
28. 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.





29. REMOVE TRANSMISSION
a. Remove the 10 bolts and ground strap.
b. Remove the transmission together with the torque converter clutch from the engine.





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

INSTALLATION
1. INSTALL DRIVE PLATE

HINT:
- The mounting bolts are tightened in 2 progressive steps (steps (c) and (e)).
- If any one of the mounting bolts is broken or deformed, replace it.





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 spacer on the crankshaft.
c. Install and uniformly tighten the 8 mounting bolts in several passes, in the sequence shown.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
If any one of the mounting bolts does not meet the torque specification, replace the mounting bolt.





d. Mark the mounting bolt with paint.
e. Retighten the mounting bolts by 90° in the numerical order shown.
f. Check that the painted mark is now at a 90° angle to (e).





2. INSTALL TRANSMISSION TO ENGINE
a. Check the torque converter clutch installation.
b. Attach the transmission to the engine.
c. Install the ground strap and 10 bolts.
Torque:
37 Nm (380 kgf-cm, 27 ft. lbs.) for 14 mm head
72 Nm (730 kgf-cm, 53 ft. lbs.) for 17 mm head
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: 48 Nm (490 kgf-cm, 35 ft. lbs.)

HINT: First install the black colored bolt, install the other bolts.





c. Install the flywheel housing under cover with the 2 bolts.
Torque: 18 Nm (185 kgf-cm, 13 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
Connect the connectors and wire:
- Connect the VSV connector.
- Connect the PNP switch connector.
- Connect the solenoid connector.
- Connect the direct clutch speed sensor connector.
- Connect the engine wire to 3 wire clamps.
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.
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: 68 Nm (700 kgf-cm, 50 ft. lbs.)
g. Install the 2 hole plugs.
h. Remove the engine chain hoist.
i. Install the No.1 V-bank cover bracket to the No.2 engine hanger with the nut.
8. INSTALL HEAT INSULATORS FOR FRONT SIDE OF FRONT EXHAUST PIPE
9. INSTALL PS GEAR HOUSING





a. 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 2 PS oil tube with the bolt.





d. Install the bolt holding the sliding yoke to the steering intermediate shaft.
Torque: 35 Nm (360 kgf-cm, 26 ft. lbs.)





10. INSTALL TRANSMISSION CONTROL ROD
Install the control rod with the 2 clips.





11. INSTALL A/C COMPRESSOR
a. Install the A/C compressor, compressor stay and wire bracket with the 3 bolts and nut.
Torque:
49 Nm (500 kgf-cm, 36 ft. lbs.) for bolt
29 Nm (300 kgf-cm, 21 ft. lbs.) for nut
b. Connect the A/C compressor connector.
c. Install the wire clamp.





12. INSTALL PS PUMP
a. Install the PS pump with the 2 bolts and nut. Alternately tighten the bolts and nut.
Torque:
39.2 Nm (400 kgf-cm, 29 ft. lbs.) for bolts
43.1 Nm (440 kgf-cm, 32 ft. lbs.) for nut
b. Connect the PS oil pressure switch connector.
c. Install the RH engine under cover with the 2 screws.
13. INSTALL PROPELLER SHAFT
14. INSTALL CENTER FRONT FLOOR BRACE
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
15. INSTALL HEAT INSULATORS





16. INSTALL TWC
Install a new gasket and the TWC with 3 new nuts. Install the 2 TWC.
Torque: 62 Nm (630 kgf-cm, 46 ft. lbs.)
17. INSTALL CENTER AND FRONT EXHAUST PIPE
18. INSTALL HEATED OXYGEN SENSORS
Install the 2 oxygen sensors to the front exhaust pipe.
Torque: 44 Nm (450 kgf-cm, 32 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. CONNECT ENGINE WIRE TO ECM BOX
a. Install the engine wire grommet to the ECM box.
b. Connect these connectors:
- Connect the 3 engine ECM connectors.
- Connect the 4 wire harness connectors.
- Connect the 2 junction connectors.
c. Install these parts:
- Install the ECM hood.
- Install the ECM cover.
20. CONNECT CONNECTORS, WIRE, STRAPS, CLAMPS AND HOSES
- Connect the generator wire to generator.
- Connect the wire for generator wire to wire clamp on generator.
- Connect the ground cable to stay on generator.
- Connect the PS oil hose to No. 1 oil pan.
- Connect the 2 PS air hoses to hose clamp on No. 3 RH timing belt cover.
- Connect the hose clamp for PS air hose.
- Connect the PS air hose to upper intake manifold.
- Connect the starter cable to battery.
- Connect the ground strap to body.
- Connect the 2 heater hoses.
- Connect the fuel inlet hose (rear fuel pipe) to fuel main tube.





21. INSTALL FRONT SUSPENSION MEMBER BRACE
Install the brace with the 6 bolts.
Torque: 58 Nm (590 kgf-cm, 43 ft. lbs.)
22. INSTALL DRIVE BELT
23. INSTALL RADIATOR ASSEMBLY
24. INSTALL INTAKE AIR CONNECTOR PIPE
25. INSTALL AIR CLEANER ASSEMBLY
26. INSTALL AIR CLEANER INLET
27. FILL WITH ENGINE COOLANT
28. FILL WITH ENGINE OIL
29. START ENGINE AND CHECK FOR LEAKS
30. INSTALL V-BANK COVER
31. INSTALL ENGINE UNDER COVER
32. INSTALL HOOD
33. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
34. RECHECK ENGINE COOLANT AND OIL LEVELS