Engine: Service and Repair

ENGINE ASSEMBLY






Removal and Installation

WARNING: Place chocks at the front and back of the rear wheels. For engines not equipped with slingers, attach proper slingers and bolts as described in the Parts Catalog.

CAUTION:
^ Do not start working until the exhaust system and coolant are cool.
^ If items or work required are not covered by the engine main body section, refer to the applicable sections.
^ Use the correct supporting points for lifting and jacking. Refer to LIFTING POINT.
^ In removing the drive shaft, be careful not to damage the grease seals on the transaxle.
^ Before separating the engine and transaxle, remove the crankshaft position sensor (POS) from the assembly.
^ Be sure not to damage the edge of the crankshaft position sensor (POS) or the ring gear teeth.

REMOVAL
1. Release fuel pressure. Refer to FUEL PRESSURE RELEASE.
2. Remove engine cover using power tool.
3. Disconnect the fuel rail at the fuel hose quick connector (engine side). Refer to INTAKE MANIFOLD.
4. Drain the engine oil. Refer to Changing Oil Filter.
5. Drain the engine coolant. Refer to DRAINING ENGINE COOLANT.
6. Remove the engine hood assembly.
7. Remove the battery, battery hold downs, and battery tray. Refer to BATTERY.
8. Disconnect the mass air flow sensor electrical connector.
9. Remove the air duct and air cleaner case assembly.
10. Disconnect the heater hoses.
11. Remove the radiator and radiator fan assembly.
12. Remove the generator. Refer to Removal.
13. Remove the left and right drive shafts. Refer to Removal.
14. Remove the engine undercover.
15. Dismount the A/C compressor with piping connected and secure with wire to the radiator support.
16. Disconnect the transaxle shift control cables.
17. Disconnect the brake power booster vacuum hose.
18. Disconnect the following engine compartment electrical harness connectors:
^ Heated oxygen sensor 1 (ULEV only) or Air fuel ratio (A/F) sensor 1 (SULEV only)
^ Starter
^ Coolant temperature sensor
^ Camshaft position sensor (PHASE)
^ EVAP canister purge volume control solenoid
^ Backup lamp switch
^ Vehicle speed sensor
^ Electric throttle control actuator
^ Ignition coils
^ Fuel injector harness
^ Engine ground straps
^ Intake valve timing control solenoid
^ Transaxle sensors (A/T only)
^ Crankshaft position sensor (POS)
^ Knock sensor
^ Oil pressure switch
^ Power valve actuator
^ Power steering pressure switch
19. Remove clutch operating cylinder from transaxle with line connected and position aside (M/T models).
20. Remove engine coolant reservoir tank.
21. Remove front exhaust tube.
22 Dismount the power steering pump with piping connected and position it aside with wire.





23. Install engine slingers into front left cylinder head and rear right cylinder head.
^ Use generator bracket bolt holes for the front slinger.
^ Use the proper slingers and bolts as described in the Parts Catalog.
Slinger bolts - front: 43.2 - 52.9 Nm (4.4 - 5.3 kg-m, 32 - 39 ft. lbs.)
Slinger bolts - rear: 24.5 - 31.4 Nm (2.5 - 3.2 kg-m, 18 - 23 ft. lbs.)
24. Support the engine/transaxle assembly with engine lifting equipment from the top with the vehicle raised on a hoist.





25. Remove the center member. Remove front and rear engine mounting insulator through-bolt and the center member bolts.
26. Remove RH engine mounting insulator.
27. Remove LH transaxle mounting insulator through-bolts.
28. Lower the engine/transaxle assembly from the engine compartment.
29. Remove the starter motor. Refer to Removal.
30. Separate the engine and transaxle.

INSTALLATION





Installation is in the reverse order of removal.
Do not allow oil to get on mounting insulators. Be careful not to damage mounting insulators. If parts have a direction mark (arrow) this indicates front of the vehicle, and the parts must be installed according to the identification mark.

INSPECTION AFTER INSTALLATION
Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Refer to RECOMMENDED FLUIDS AND LUBRICANTS.
^ Use procedure below to check for fuel leakage.
^ Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points.
^ 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 fuel, exhaust gas, or any oils/fluids including engine oil and engine coolant.
^ Bleed air from passages in lines and hoses, such as in cooling system.
^ After cooling down engine, again check oils/fluids including engine oil and engine coolant. Refill to specified level, if necessary.





^ Summary of the inspection items: