Engine: Service and Repair

ENGINE ASSEMBLY

REMOVAL
1. Release fuel pressure in fuel feed line.
2. Disconnect negative cable at battery.
3. Remove engine hood.
4. Drain engine oil.
5. Drain coolant.
6. Remove radiator, radiator fan shroud, cooling fan and radiator reservoir. Refer to Cooling System.





7. Disconnect accelerator cable and A/T throttle cable (for A/T vehicle) from throttle body.
8. Remove strut tower bar and surge tank cover.
9. Disconnect IAT sensor coupler then remove air cleaner upper case, intake air hose, intake air pipe and surge tank pipe as a component.
10. Remove engine oil level gauge guide and A/T fluid level gauge guide (for A/T vehicle).
11. Remove ignition coil covers.





12. Disconnect following electric lead wires:
^ Injector wire coupler
^ CMP sensor coupler
^ Ignition coil couplers
^ CKP sensor coupler
^ TP sensor coupler
^ MAF sensor coupler
^ IAC valve coupler
^ Earth wire from surge tank
^ EVAP canister purge valve coupler
^ EGR valve coupler
^ Oxygen sensor -1 and -2 couplers (Refer to "Exhaust Manifold" for disconnection)
^ Coolant temperature sensor coupler
^ Generator wires
^ Starter wires
^ Oil pressure wire
^ P/S pump wire
^ Earth wire from generator bracket
13. Remove clamps and brackets.





14. Disconnect following hoses:
^ Heater hose from heater water pipe
^ Heater hose from water outlet cap
^ EVAP canister hose from canister pipe
^ Brake booster vacuum hose
^ Tank pressure control solenoid vacuum valve hose from intake manifold
15. Remove IAC valve and EVAP canister purge valve.





16. Disconnect following hoses at the location shown in figure:
^ Fuel feed hose from fuel feed pipe
^ Fuel return hose from fuel return pipe
17. Remove EVAP canister.
18. Remove P/S pump assembly. Refer to Steering; Power Steering Pump.
19. Remove A/C compressor assembly. Refer to Heating and Air Conditioning.
20. Remove steering shaft lower assembly. Refer to Steering; Steering Shaft.
21. Raise vehicle.
22. Remove front differential housing with differential from chassis if equipped. Refer to Transmission and Drivetrain.
23. Remove exhaust No.1 pipe. Refer to Exhaust System.
24. Remove exhaust manifold stiffener from transmission.





25. Remove A/T fluid hose clamps from engine mounting bracket (for A/T vehicle).
26. Remove clutch housing lower plate.
27. Remove torque converter bolts (for A/T vehicle).
28. Remove starter motor.
29. Lower vehicle.
30. Support transmission. For A/T vehicle, don't jack under A/T oil pan to support transmission.





31. Remove bolts and nuts fastening cylinder block and transmission.
32. Install lifting device.





33. Disconnect engine side mounting brackets to engine mountings.
34. Before lifting engine, check to ensure all hoses, wires and cables are disconnected from engine.
35. Remove engine assembly from chassis and transmission by sliding toward front, and then, carefully hoist engine assembly.

INSTALLATION
Reverse removal procedure for installation, noting following points:
1. Lower engine assembly into engine compartment. Connect engine to transmission and engine side mounting brackets to engine mountings.





2. Tighten nuts fastening engine side mounting brackets and engine mountings.
Tightening Torque (a): 50 Nm (5.0 kg-m, 36.5 ft. lbs.)





3. Tighten bolts and nuts fastening cylinder block and transmission to specified torque.
Tightening Torque (b): 80 Nm (8.0 kg-m, 58.0 ft. lbs.)
4. Remove lifting device





5. Tighten torque converter bolts to specified torque (for A/T vehicle).
Tightening Torque (c): 65 Nm (6.5 kg-m, 47.0 ft. lbs.)





6. Tighten bolts and nuts of exhaust No.1 pipe to specified torque.
Tightening Torque (d): 50 Nm (5.0 kg-m, 36.5 ft. lbs.)
7. Install front differential housing with differential to chassis if removed. Refer to Transmission and Drivetrain for installation.
8. Install steering shaft lower assembly. Refer to Steering; Steering Shaft.
9. Install A/C compressor assembly. Refer to Heating and Air Conditioning.
10. Install P/S pump assembly. Refer to Steering; Power Steering Pump.
11. Connect hoses, cables and electric wires.
12. Adjust accelerator cable and A/T throttle cable (for A/T vehicle).
13. Refill engine with engine oil referring to Engine Lubrication.
14. Refill cooling system, referring to Cooling System.
15. Check to ensure that all fasteners and clamps are tightened.
16. Upon completion of installation, verify that there is no fuel leakage, coolant leakage, P/S fluid leakage or exhaust gas leakage at each connection.