Engine: Service and Repair

REMOVAL
1. REMOVE HOOD
2. REMOVE ENGINE UNDER COVER AND OIL PAN PROTECTOR
3. DRAIN ENGINE COOLANT
4. ENGINE OIL
5. REMOVE V-BANK COVER AND ENGINE SIDE ROOM COVERS
6. REMOVE AIR CLEANER INLET
7. REMOVE AIR CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY
8. REMOVE DRIVE BELT
9. DISCONNECT RADIATOR LOWER HOSE FROM WATER INLET HOUSING
10. DISCONNECT RADIATOR UPPER HOUSE FROM WATER BYPASS JOINT
11. DISCONNECT WIRE, CABLES AND HOSES
- Disconnect the brake booster vacuum hose from the intake manifold.
- Disconnect the 2 heater hoses from the water bypass pipe.
- Disconnect the 2 ground straps from the body.
- Disconnect the starter cable from the battery.
- Disconnect the fuel inlet hose from the fuel main tube.
- Disconnect the PS air hose from the intake manifold.
- Disconnect the EVAP hose from the VSV for EVAP.
- Disconnect the 2 A/T oil cooler hoses from the radiator.
- Disconnect the 2 electric cooling fan connectors.
- Disconnect the 2 electric cooling fan ECU connectors.
12. DISCONNECT ENGINE WIRE FROM ECM BOX
a. Remove the ECM box cover.
b. Disconnect the 5 ECM connectors and 2 wire connectors.
c. Disconnect the grommet and engine wire from the ECM box.
13. DISCONNECT HEATED OXYGEN SENSORS FROM FRONT EXHAUST PIPE





14. REMOVE FRONT EXHAUST PIPE, CENTER EXHAUST PIPE AND TAIL PIPES
15. REMOVE TWC
16. REMOVE HEAT INSULATORS
17. REMOVE PROPELLER SHAFT
18. DISCONNECT A/C COMPRESSOR FROM ENGINE





19. 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 PH fender apron.





20. DISCONNECT PS OIL TUBE
Using SST, disconnect the PS oil tube from the PS gear housing.
SST 09633-00020
21. DISCONNECT SLIDING YOKE FROM INTERMEDIATE SHAFT
22. REMOVE FRONT STABILIZER BAR





23. DISCONNECT SHOCK ABSORBER FROM LOWER ARM
Remove the bolt and nut, disconnect the shock absorber from the lower arm.
24. DISCONNECT LEVEL HEIGHT SENSOR LINKAGE FROM LOWER ARM
25. DISCONNECT LOWER ARM FROM STEERING KNUCKLE
Remove the 2 bolts, disconnect the lower arm from the steering knuckle.
26. REMOVE ENGINE AND TRANSMISSION ASSEMBLY FROM VEHICLE





a. Attach the engine chain hoist to the engine hangers and hold the engine tightly.





b. Remove the nut, and disconnect the transmission control rod from the shift lever.
c. Remove the 4 bolts and disconnect the rear mounting member from the body.
d. Set the engine jack.





e. Remove the 4 bolts and disconnect the front suspension member from the body.





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

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

g. Using a engine sliding device, and place the engine and transmission assembly onto the stand.





27. REMOVE FRONT SUSPENSION MEMBER FROM ENGINE
Remove the 2 nuts and front suspension member with the steering gear housing.
28. DISCONNECT ENGINE WIRE FROM TRANSMISSION
a. Disconnect the POP switch connector.
b. Disconnect the solenoid connector.
c. Disconnect the direct clutch speed sensor connector.
d. Disconnect the PNP switch connector.
e. Disconnect the 4 engine wire clamps from the bracket.
29. REMOVE OIL DIPSTICK GUIDE AND DIPSTICK FOR TRANSMISSION
30. REMOVE OIL COOLER PIPES FOR TRANSMISSION
31. REMOVE TORQUE CONVERTER CLUTCH BOLTS





a. Remove the 2 bolts and flywheel housing under cover.





b. Turn the crankshaft pulley bolt to again access to each bolt.
c. Hold the crankshaft pulley bolt with a wrench, and remove the 6 bolts.





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





33. 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 4 engine wire clamps to the bracket.





7. INSTALL SUSPENSION MEMBER TO ENGINE
Install the suspension member with the 4 nuts and to the engine.
Torque: 70 Nm (714 kgf-cm, 52 ft. lbs.)





8. SET ENGINE JACK

NOTICE: Using a chain, hold the engine tightly.

9. INSTALL ENGINE AND TRANSMISSION ASSEMBLY IN VEHICLE
a. Raise the engine into the engine compartment.





b. Connect the suspension member with the 4 bolts to the body.
Torque:
A: 176 Nm (1,795 kgf-cm, 130 ft. lbs.)
B: 157 Nm (1,600 kgf-cm, 116 ft. lbs.)





c. Install the rear engine mounting with the 4 bolts.
Torque: 22.5 Nm (260 kgf-cm, 19 ft. lbs.)
d. Remove the engine jack and chain.





10. CONNECT LOWER ARM TO STEERING KNUCKLE
Connect the lower arm to the steering knuckle with the 2 bolts.
11. CONNECT LEVEL HEIGHT SENSOR LINKAGE TO LOWER ARM
12. CONNECT SHOCK ABSORBER TO LOWER ARM
Connect the shock absorber to the lower arm with the bolt and nut.
13. INSTALL FRONT STABILIZER BAR
14. CONNECT SLIDING YOKE TO INTERMEDIATE SHAFT





15. CONNECT PS OIL TUBE
Using SST, connect the PS oil tube to the PS gear housing.
SST 09633-00020





16. INSTALL PS PUMP AND OIL RESERVOIR
a. Install the PS oil reservoir to the RH fender apron with the 3 bolts.
b. Install the PS pump to the engine with the 2 bolts and nut.
17. BLEED POWER STEERING SYSTEM
18. CONNECT A/C COMPRESSOR TO ENGINE
19. INSTALL PROPELLER SHAFT
20. INSTALL HEAT INSULATORS
21. INSTALL TWC
22. INSTALL FRONT EXHAUST PIPE, CENTER EXHAUST PIPE AND TAIL PIPES
23. CONNECT HEATED OXYGEN SENSORS TO FRONT EXHAUST PIPE





24. CONNECT ENGINE WIRE FROM ECM BOX
a. Connect the grommet and engine wire to the ECM box.
b. Connect the 5 ECM connectors and 2 wire connectors.
c. Install the ECM box cover.
25. CONNECT WIRE, CABLES AND HOSES
- Connect the 2 electric cooling fan ECU connectors.
- Connect the 2 electric cooling fan connectors.
- Connect the 2 A/T oil cooler hoses to the radiator.
- Connect the EVAP hose to the VSV for EVAP.
- Connect the PS air hose to the intake manifold.
- Connect the fuel inlet hose to the fuel main tube.
- Connect the starter cable to the battery.
- Connect the 2 ground straps to the body.
- Connect the 2 heater hoses to the water bypass pipe.
- Connect the brake booster vacuum hose to the intake manifold.
26. CONNECT RADIATOR UPPER HOSE TO WATER BYPASS JOINT
27. CONNECT RADIATOR LOWER HOSE TO WATER INLET HOUSING
28. INSTALL DRIVE BELT
29. INSTALL AIR CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY
30. INSTALL AIR CLEANER INLET
31. FILL WITH ENGINE COOLANT
32. FILL WITH ENGINE OIL
33. START ENGINE AND CHECK FOR LEAKS
34. INSTALL V-BANK COVER AND ENGINE ROOM SIDE COVER
35. INSTALL ENGINE UNDER COVER AND OIL PAN PROTECTOR
36. INSTALL HOOD
37. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
38. RECHECK ENGINE COOLANT AND OIL LEVELS