Engine: Service and Repair
Removal1. 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.
7. Disconnect accelerator cable (1) and A/T throttle cable (for A/T vehicle) (2) from throttle body
8. Remove strut tower bar and surge tank cover.
9. Disconnect IAT sensor coupler and MAF 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 the following electric lead wires:
^ Injector wire coupler
^ CMP sensor coupler
^ Ignition coil couplers
^ CKP sensor coupler
^ MAP sensor coupler
^ TP sensor (1) coupler
^ IAC valve (2) coupler
^ Earth wire (3) from surge tank
^ EVAP canister purge valve coupler
^ EGR valve coupler
^ Oxygen sensor-1 and -2 couplers.
^ Coolant temperature sensor coupler
^ Knock sensor coupler
^ Generator wires
^ Starter wires Oil pressure wire P/S pump wire
^ Earth wire from generator bracket
^ Engine block heater (if equipped)
13. Remove clamps and brackets.
14. Disconnect the following hoses:
^ Heater hose from heater water pipe
^ Heater hose from water outlet cap
^ EVAP canister hose from canister pipe
^ Brake booster vacuum hose
15. Remove EVAP canister purge valve (5).
16. Disconnect the following hoses at the location shown in the figure:
^ Fuel feed hose (1) from fuel feed pipe
^ Fuel return hose from (2) fuel return pipe
17. Remove P/S pump assembly.
18. Remove A/C compressor assembly.
19. Remove steering shaft lower assembly.
20. Raise vehicle.
21. Remove front differential housing with differential from chassis if equipped.
22. Remove exhaust No.1 pipe.
23. Remove exhaust manifold stiffener from transmission.
24. Remove A/T fluid hose clamps (1) from engine mounting bracket (2). (for A/T vehicle)
25. Remove clutch housing lower plate.
26. Remove torque converter bolts (for A/T vehicle).
27. Remove starter motor.
28. Lower vehicle.
29. Support transmission. For A/T vehicle, don't jack under A/T oil pan to support transmission.
30. Remove bolts and nuts fastening cylinder block and transmission.
31. Install lifting device.
32. Disconnect engine side mounting brackets (1) to engine mountings.
33. Before lifting engine, check to ensure all hoses, wires and cables are disconnected from engine.
34. Remove engine assembly from chassis and transmission by sliding toward front, and then, carefully hoist engine assembly.
Installation
Reverse removal procedure for installation, noting the 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
Engine side mounting bracket nut (a): 50 Nm (5.0 kgf-m, 36.5 ft. lbs.)
3. Tighten bolts and nuts fastening cylinder block and transmission to specified torque.
Tightening torque
Transmission to cylinder block bolt and nut (b): 85 Nm (8.5 kgf-m, 61.5 ft. lbs.)
4. Remove lifting device
5. Tighten torque converter bolts to specified torque (for A/T vehicle).
Tightening torque
Torque converter bolt (c): 65 Nm (6.5 kgf-m, 47.0 ft. lbs.)
6. Tighten bolts and nuts of exhaust No. 1 pipe (1) to specified torque.
Tightening torque
Exhaust No.1 pipe bolt and nut (d): 50 Nm (5.0 kgf-m, 36.5 ft. lbs.)
7. Install front differential housing with differential to chassis if removed.
8. Install steering shaft lower assembly.
9. Install A/C compressor assembly.
10. Install P/S pump assembly.
11. Connect hoses, cables and electric wires.
12. Adjust accelerator cable play and A/T throttle cable play (for A/T vehicle).
13. Refill engine with engine oil.
14. Refill 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.