Engine: Service and Repair

REMOVAL
1. Release fuel pressure in fuel feed line.
2. Remove battery.
3. Remove engine hood.





4. Drain cooling system
5. Remove radiator fan and fan shroud.
6. Remove air-intake pipe with hoses.





7. Disconnect accelerator cable and A/T kickdown cable (for 3 A/T model) or A/T throttle cable (4 A/T model) from throttle body.





8. Remove intake manifold stiffener and then release wire harnesses from clamps.
9. Remove starter motor.





10. Disconnect following electric wires:
- Distributor
- Ground wires from surge tank
- Engine oil pressure switch
- EGR solenoid vacuum valve
- Evaporative Emission (EVAP) solenoid purge valve
- Coolant (Water) temperature gauge
- Engine coolant temperature sensor
- A/C coolant (water) temperature switch
- Injectors, TP sensor and Idle Air Control (IAC) valve wires at the coupler
- Heated oxygen sensor-1
- Generator
- EGR solenoid vacuum valve (for system check) and then release wire harnesses from clamps.





11. Disconnect following hoses:
- Canister purge hose from EVAP canister purge valve
- Brake booster hose from surge tank
- Radiator outlet hose from inlet pipe
- Heater inlet and outlet hose from heater unit
- Vacuum hose for A/T from intake manifold. (3 A/T model)
- Tank pressure control solenoid vacuum valve hose from solenoid vacuum valve (if equipped)
- Manifold differential pressure sensor-hose from pressure sensor





12. Loosen bolts fastening cylinder block and transmission.
13. Hoist vehicle.
14. Drain engine oil.





15. Disconnect fuel feed and return hoses from pipes.





16. Remove right side transmission stiffener bolts (3 pieces) and loosen one bolt (4A/T model) and A/T fluid hose clamp bolt (A/T model).





17. Remove exhaust pipes.





18. Remove left side transmission stiffener (4 A/T model) and then clutch housing (torque converter housing) lower plate.





19. Remove torque converter bolts (A/T model).
Special Tool(A): 09927-56010





20. With hoses connected, detach power steering pump and/or A/C compressor with bracket from cylinder block, if equipped.

NOTE: When installing bracket fasten bolt (A) first, then fasten other bolts.





21. Remove nuts fastening cylinder block and transmission.
22. Lower vehicle.
23. Support transmission with jack. With A/T vehicle, don't jack under A/T oil pan to support transmission.





24. Install lifting device.





25. Remove engine mounting bracket bolts (R & L).
26. Before lifting engine, check to ensure all hoses, electric wires and cables are disconnected from engine.
27. Remove engine assembly from chassis and transmission by sliding towards the front side, and then carefully hoist engine assembly.

INSTALLATION





1. Lower engine assembly into engine compartment and connect engine to transmission. Hand-tighten bolts and nuts fastening cylinder block and transmission.





2. Tighten engine mounting bracket bolts (R & L).

Tightening Torque (a): 50 Nm (36.5 ft. lbs.)





3. Tighten bolts fastening cylinder block and transmission to specified torque.

Tightening Torque (a): 85 Nm (61.5 ft. lbs.)

4. Remove lifting device.





5. Reverse removal procedure for installation, noting the following.
- Tighten torque converter bolts to specified torque.

Tightening Torque (a): 65 Nm (47.0 ft. lbs.)





- Tighten nuts fastening cylinder block and transmission and transmission stiffener bolts (left side for 4 A/T and M/T model) to specified torque.

Tightening Torque
(a): 50 Nm (36.5 ft. lbs.)
(b): 85 Nm (61.5 ft. lbs.)





- Tighten nuts and bolts of exhaust pipes to specified torque.

Tightening Torque (a): 50 Nm (36.5 ft. lbs.)





- Tighten transmission stiffener bolts (right side) to specified torque (4 A/T and M/T model).

Tightening Torque
(a): 50 Nm (36.5 ft. lbs.)
(b): 29 Nm (21.0 ft. lbs.)





- Tighten flare nut of fuel feed pipe to specified torque. Be sure to use back-up wrench.

Tightening Torque (a): 45 Nm (32.5 ft. lbs.)

6. Adjust water pump drive belt tension.
7. Adjust power steering pump belt tension or A/C compressor belt tension, if equipped.
8. Adjust accelerator cable play and A/T kickdown cable (for 3 A/T model) or A/T throttle cable (for 4 A/T model) play.
9. Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
10. Refill engine with engine oil, referring to item ENGINE OIL CHANGE.
11. Refill cooling system.
12. Verify that there is no fuel leakage, coolant leakage and exhaust gas leakage at each connection.