Engine: Service and Repair

REMOVAL
1. REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. DRAIN ENGINE OIL
4. REMOVE ENGINE COVER
Remove the 4 nuts and engine cover.
5. REMOVE AIR CLEANER INLET
6. DISCONNECT BRAKE BOOSTER VACUUM HOSE
7. DISCONNECT RADIATOR UPPER AND LOWER HOSES FROM ENGINE
8. DISCONNECT ACCELERATOR CABLE FROM ENGINE





9. REMOVE INTAKE AIR RESONATOR
a. Disconnect the MAF meter connector.
b. Disconnect the engine wire clamp from the air cleaner case.
c. Disconnect the PCV hose from the No. 2 cylinder head cover.
d. Loosen the 2 hose clamp bolts, remove the intake air resonator from the throttle body.
10. M/T: REMOVE DRIVE BELT TENSIONER ABSORBER
Remove the 2 nuts and absorber.
11. REMOVE DRIVE BELT





12. REMOVE FRONT SUSPENSION MEMBER BRACE
Remove the bolts and brace.
13. M/T: REMOVE TRANSMISSION SHIFT LEVER
14. 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 2 engine wire clamps from the clamp brackets.





15. 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.
16. 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.





e. Loosen the nut.
f. Using a torx socket (E10), remove the stud bolt and nut.
g. Disconnect the PPS solenoid valve connector.
h. Disconnect the A/C compressor connector.
i. Remove the 2 bolts, and disconnect the compressor from the engine.

HINT: Put aside the vane pump and compressor, and suspend it securely.

17. M/T: DISCONNECT CLUTCH RELEASE CYLINDER FROM TRANSMISSION
18. REMOVE PROPELLER SHAFT





19. A/T: REMOVE TRANSMISSION CONTROL ROD
Remove the 2 nuts and control rod.
20. REMOVE FRONT AND CENTER EXHAUST PIPES





21. DISCONNECT SLIDING YOKE
a. Check the steering wheel at the straight-ahead position, and place matchmarks on the sliding yoke and intermediate shaft.
b. Remove the bolt, and disconnect the sliding yoke from the steering intermediate shaft.
c. Disconnect the PS pressure switch connector and wire clamp.





22. REMOVE STABILIZER BAR
a. Remove the 2 nuts from the stabilizer bar links.
b. Remove the 4 bolts, 2 stabilizer bar brackets and 2 bushings.





23. DISCONNECT SHOCK ABSORBER
Remove the bolt and nut, and disconnect the shock absorber from the shock absorber bracket.
24. DISCONNECT LOWER ARM
a. Remove the nut, and disconnect the height level sensor from the lower arm.
b. Remove the 2 bolts, and disconnect the lower arm from the steering knuckle.





25. SET ENGINE JACK

NOTICE: Using chain, hold the engine tightly.





26. DISCONNECT REAR ENGINE MOUNTING MEMBER
Remove the 4 bolts and rear engine mounting member.





27. DISCONNECT SUSPENSION MEMBER
Remove the 4 bolts, and disconnect the suspension member from the body.





28. REMOVE ENGINE AND TRANSMISSION ASSEMBLY
a. Remove the engine out of vehicle slowly and carefully.

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

b. Using a engine sliding device, and place the engine and transaxle assembly onto the stand.





29. REMOVE SUSPENSION MEMBER FROM ENGINE
Remove the 4 nuts and suspension member with the steering gear housing from the engine.





30. A/T: REMOVE OIL DIPSTICK AND GUIDE
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.
d. Remove the O-ring from the dipstick guide.





31. REMOVE EXHAUST MANIFOLD
a. Remove the case clamp.
b. Disconnect the heated oxygen sensor (bank 2 sensor 1) connector.
c. Remove the 8 nuts, exhaust manifold and 2 gaskets.





32. A/T: REMOVE OIL COOLER PIPES
a. Remove the 3 bolts and pipe clamps.
b. Loosen the 2 union nuts, and remove the 2 oil cooler pipes.





33. A/T: 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.





34. REMOVE 4 BOLTS HOLDING NO. 1 OIL PAN TO TRANSMISSION
35. REMOVE STARTER
a. Disconnect the starter connector.
b. Remove the 2 bolts, clamp bracket and starter.
36. 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.
37. M/T: DISCONNECT ENGINE WIRE FROM TRANSMISSION
a. Disconnect the VSS connector.
b. Disconnect the back-up light switch connector.





38. 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.
39. A/T: REMOVE DRIVE PLATE
Remove the 8 bolts, rear plate, drive plate and front spacer.
40. M/T: REMOVE CLUTCH COVER AND DISC

INSTALLATION
1. A/T: 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, in the sequence shown.
Torque: 83 Nm (850 kgf-cm, 61 ft. lbs.)
2. M/T: INSTALL CLUTCH DISC AND COVER
3. A/T: INSTALL TORQUE CONVERTER CLUTCH INSTALLATION





4. INSTALL TRANSMISSION TO ENGINE
a. Attach the transmission to the engine.
b. Install the ground wire and 5 bolts.
Torque: 72 Nm (730 kgf-cm, 53 ft. lbs.)
5. A/T: 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.
6. M/T: CONNECT ENGINE WIRE TO TRANSMISSION
a. Connect the VSS connector.
b. Connect the back-up light switch connector.
7. 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.





8. INSTALL 4 BOLTS HOLDING NO. 1 OIL PAN TO TRANSMISSION
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)





9. A/T: 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.
10. A/T: INSTALL OIL COOLER PIPE





11. 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.





12. A/T: INSTALL OIL DIPSTICK GUIDE AND DIPSTICK
a. Install a new Oaring 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.





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





14. SET ENGINE JACK

NOTICE: Using a chain, hold the engine tightly.

15. INSTALL ENGINE AND TRANSMISSION ASSEMBLY IN VEHICLE
a. Raise the engine into the engine compartment.
b. Keep the engine level, and align RH and LH mountings with the insulator.





16. CONNECT SUSPENSION MEMBER
Connect the suspension member with the 4 bolts to the body.
Torque: 70 Nm (714 kgf-cm, 52 ft. lbs.)





17. CONNECT REAR ENGINE MOUNTING MEMBER
Install the rear engine mounting member with the 4 bolts.
Torque:
25.5 Nm (260 kgf-cm, 19 ft. lbs.) for bolt
13.5 Nm (135 kgf-cm, 10 ft. lbs.) for nut
18. REMOVE ENGINE JACK





19. CONNECT LOWER ARM
a. Connect the lower arm with the 2 bolts to the steering knuckle.
Torque: 245 Nm (2,500 kgf-cm, 181 ft. lbs.)
b. Connect the height level sensor to the lower arm.
20. CONNECT SHOCK ABSORBER
Connect the shock absorber with the bolt and nut.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)





21. INSTALL STABILIZER
a. Install the 2 bushings and 2 stabilizer bar brackets to the stabilizer bar.
b. Install the stabilizer bar with the 4 bolts and 2 nuts.
Torque:
18 Nm (180 kgf-cm, 13 ft. lbs.) for bolt
49 Nm (500 kgf-cm, 36 ft. lbs.) for nut





22. CONNECT SLIDING YOKE
a. Align the matchmarks and connect the sliding yoke to the steering intermediate shaft.
b. Install the bolt holding the sliding yoke to the steering intermediate shaft.
Torque: 35 Nm (360 kgf-cm, 26 ft. lbs.)
c. Connect the PS pressure switch and wire clamp.
23. INSTALL FRONT AND CENTER EXHAUST PIPE
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
24. A/T: INSTALL TRANSMISSION CONTROL ROD





Install the control rod with the 2 nuts.
Torque: 16 Nm (163 kgf-cm, 12 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.)
25. M/T: INSTALL CLUTCH RELEASE CYLINDER TO TRANSMISSION
26. 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 PPS solenoid valve connector.





f. Install the vane pump assembly with the 3 bolts and plate washer.
Torque:
58 Nm (590 kgf-cm, 43 ft. lbs.) for bolt A
52 Nm (530 kgf-cm, 38 ft. lbs.) for bolt B





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.
27. M/T: INSTALL TRANSMISSION SHIFT LEVER
a. Install the shift lever with the 4 bolts.
Torque: 8 Nm (82 kgf-cm, 71 inch lbs.)





28. 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 hood.
29. CONNECT CLAMPS, WIRES, CONNECTORS, HOSES, CABLE AND STRAP
a. Connect the 2 engine wire clamps to the clamp brackets.
b. Connect the igniter connector.





c. Connect the ground cable to the bracket on the cylinder block.
d. Connect the engine wire clamp to the wire clip of the generator.
e. Connect the generator wire.
f. Connect the heated oxygen sensor (bank 1 sensor 1) connector.
g. Connect the heated oxygen sensor (bank 1 sensor 2) connector.





h. Connect the EVAP hose to the pipe (from charcoal canister).
i. Connect the heater hose to the heater pipe.
j. Connect the heater hose to the water bypass pipe.
k. Connect the ground strap to the dash panel.
l. Connect the fuel inlet hose to the fuel pipe support.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)
m. Connect the starter wire to the terminal and manifold stay.
n. Connect the ground wire to the floor.





30. INSTALL FRONT SUSPENSION MEMBER BRACE
Install the brace with the 3 bolts.
Torque:
Bolt A: 119 Nm (1,210 kgf-cm, 88 ft. lbs.)
Bolt B: 58 Nm (590 kgf-cm, 43 ft. lbs.)
31. INSTALL DRIVE BELT
32. M/T: INSTALL DRIVE BELT TENSIONER ABSORBER
Install the absorber with the 2 nuts.
Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.)
33. CONNECT ACCELERATOR CABLE TO ENGINE





34. INSTALL INTAKE AIR RESONATOR
a. Connect the intake air resonator to the throttle body.
b. Tighten the hose clamp bolt holding the intake air resonator to the throttle body.
c. Connect the MAF meter connector.
d. Connect the engine wire clamp to the air cleaner case.
e. Connect the PCV hose to the No.2 cylinder head cover.
35. CONNECT RADIATOR UPPER AND LOWER HOSES
36. CONNECT BRAKE BOOSTER VACUUM HOSE
37. INSTALL AIR CLEANER INLET
38. INSTALL ENGINE COVER
Install the engine cover with the 4 nuts.
39. FILL WITH ENGINE COOLANT
40. FILL WITH ENGINE OIL
41. START ENGINE AND CHECK FOR LEAKS
42. INSTALL ENGINE UNDER COVER

NOTICE: Be careful not to damage the body or glass with the hood end.

43. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
44. RECHECK ENGINE COOLANT AND OIL LEVELS