Engine: Service and Repair
Removal and Installation
WARNING: For engines not equipped with engine slingers, attach proper slingers and bolts.
Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for unavoidable reasons, support at the rear axle jacking point with transmission jack or similar tool before starting work, in preparation for the backward shift of center of gravity.
CAUTION: Always be careful to work safely, avoid forceful or uninstructed operations.
Do not start working until exhaust system and coolant are cool enough.
Always use the support point specified for lifting.
ENGINE REMOVAL
Outline
At first, remove engine and transmission assembly with suspension member downward. Then separate engine from transmission.
Preparation
1. Perform The Fuel Pressure Release.
2. Disconnect both battery cables.
3. Remove the following parts:
- Engine hood.
- Strut tower bar.
- Engine cover.
- Battery cover and brake booster cover.
- Wiper arm and cowl top cover.
- Drive belts.
- LH/RH front wheel.
4. Drain engine coolant from radiator.
5. Remove air duct and air cleaner case assembly.
6. Discharge refrigerant from A/C circuit.
7. Remove radiator assembly, reservoir tank and hoses.
Engine Room
1. Disconnect heater hose at engine-side, and fit a plug onto hose end to prevent coolant leak.
2. Disconnect grounding wire (between vehicle to LH cylinder head).
3. Disconnect battery plus harness at vehicle side and temporarily fasten it on engine.
4. Disconnect A/C piping from A/C compressor, and temporarily fasten it on vehicle with a rope.
5. Remove engine room harness connectors shown in the figure.
6. Disconnect body ground cables.
7. Disconnect brake booster vacuum hose.
8. Disconnect fuel feed hose and EVAP hose.
CAUTION: Fit plugs onto disconnected hoses to prevent fuel leak.
9. Remove reservoir tank of power steering oil pump, and piping from vehicle, and temporarily secure them on engine.
CAUTION: When temporarily securing, keep the reservoir tank upright to avoid a fluid leak.
Passenger Room Side
Follow procedure below to disconnect engine room harness connectors at passenger room side, and temporarily secure them on engine.
1. Remove passenger-side kicking plate, dashboard side trim, and glove box.
2. Disconnect engine room harness connectors at unit sides TCM, ECM and other.
3. Disengage intermediate fixing point. Pull out engine room harnesses to engine room side, and temporarily secure them on engine.
CAUTION: When pulling out harnesses, take care not to damage harnesses and connectors.
After temporarily securing, cover connectors with vinyl or similar material to protect against foreign material adhesion.
Vehicle Underbody
1. Remove exhaust front tube.
2. Disconnect steering lower joint, and release steering shaft.
3. Remove propeller shaft.
CAUTION: Do not impact or damage propeller shaft tube.
4. Disengage shift control linkage at selector lever side. Then, temporarily secure it on transmission, so that it does not sag.
5. Remove rear plate cover from upper oil pan. Then, remove bolts fixing drive plate to torque converter.
6. Remove bolts fixing transmission to lower rear side of upper oil pan.
7. Remove front stabilizer.
8. Remove left and right end ball joint of steering linkage.
9. Remove left and right transverse link from suspension member.
Removal Work
1. Use a manual lift table caddy (commercial service tool) or equivalently rigid tool such as a transmission jack. Securely support bottom of suspension member and transaxle.
CAUTION: Put a piece of wood or something similar as the supporting surface, secure a completely stable condition.
2. Remove rear engine mounting member mounting bolt.
3. Remove suspension member mounting bolt and nut.
4. Carefully lower jack, or raise lift to remove engine, transmission, and suspension member assembly. When performing work, observe the following:
CAUTION: Confirm there is no interference with vehicle.
Check that all connection points have been disconnected.
Keep in mind the center of vehicle gravity changes. If necessary, use jack(s) to support vehicle at rear jacking point(s) to prevent it from falling it off the lift.
Separation Work
1. Install engine slingers into front of right bank cylinder head and rear of left bank cylinder head.
Slinger bolts:...................24.5 - 31.4 Nm (2.5 - 3.2 kgf-cm, 18 - 23 ft. lbs.)
To protect rocker cover against damage caused by tilting of engine slinger, insert spacer between cylinder head and engine rear lower slinger, in direction shown in figure.
NOTE: Spacer is a component part of engine rear upper slinger assembly.
2. Remove power steering oil pump from engine side.
3. Remove engine mounting insulator under side nut.
4. Lift with hoist and separate engine and transmission assembly from suspension member.
CAUTION: Before and during this lifting, always check if any harnesses are left connected.
Avoid damage to and oil/grease smearing or spills onto engine mounting insulator.
5. Remove alternator.
6. Remove starter motor.
7. Separate engine from transmission assembly.
8. Remove engine mounting insulator and bracket.
INSTALLATION
Install in the reverse order of removal paying attention to the following For a location with a positioning pin, insert it securely into hole of mating part.
When installing front engine mounting bracket on cylinder block, tighten 2 upper bolts (shown as A in figure) first. Then tighten 2 lower bolts (shown as B in figure). (Left and right sides)
Tighten rear engine mounting member mounting bolts in numerical order shown in figure.
INSPECTION AFTER INSTALLATION
Before starting engine, check the levels of coolant, lubrications and working oils. If less than required quantity, fill to the specified level.
Use procedure below to check for fuel leakage.
1. Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points.
2. Start engine. With engine speed increased, check again for fuel leakage at connection points.
- Run engine to check for unusual noise and vibration.
- Warm up engine thoroughly to make sure there is no leakage of coolant, lubricants, working oil, fuel and exhaust gas.
- Bleed air from passages in pipes and tubes of applicable lines, such as in cooling system.
- After cooling down engine, again check amounts of coolant, lubricants, oil, and fluid. Refill to specified level, if necessary.