Engine: Service and Repair
Engine Assembly Removal and InstallationRemoval
1) Release fuel pressure in fuel feed line, referring to Fuel Pressure Relief Procedure.
2) Remove battery and battery tray.
3) Remove surge tank cover.
4) Remove air cleaner assembly and air cleaner outlet hose, referring to Air Intake System Components.
5) Drain engine oil, referring to Engine Oil and Filter Change.
6) Drain coolant.
7) Drain transmission oil or A/T fluid.
8) Disconnect the following electric wires.
^ MAP sensor (1)
^ Injector harness
^ Electric throttle body (2)
^ EVAP canister purge valve (3)
^ Ignition coil assemblies (4)
^ CMP sensor (5)
^ Generator
^ Starting motor
^ Pressure switch of P/S pump (6)
^ Magnet clutch switch of A/C compressor (if equipped)
^ Engine oil pressure switch
^ Ground terminals
^ Knock sensor (7)
^ CKP sensor (8)
^ A/F sensor (No.1 and No.2) (9)
^ HO2S (No.1 and No.2) (10)
^ EGR valve (11)
^ ECT sensor (12)
^ Back up light switch (for M/T model)
^ Input shaft speed sensor (for A/T model) (13)
^ Output shaft speed sensor (for A/T model) (14)
^ Transmission range sensor (for A/T model) (15)
^ Transmission wire connector (for A/T model) (16)
^ Transfer actuator (if equipped) (17)
^ Center differential switch (if equipped) (18)
^ 4 L/N switch (if equipped) (19)
^ Each wire harness clamps
9) Disconnect the following hoses.
^ Brake booster hose (1) from intake manifold
^ EVAP canister purge hose (2) from fuel No.2 pipe.
^ Vacuum tank hose (3) from intake manifold
^ IMT hose from IMT valve
^ Radiator inlet hose and outlet hose from each pipe.
^ Heater inlet hose and outlet hose from each pipe
^ Fuel feed hose (4) and return hose (5) from each pipe
^ Reservoir hose from water outlet cap
^ Clutch oil pipe from transmission front case (for M/T model)
^ A/T fluid cooler hose from radiator (for A/T model)
10) Disconnect high pressure pipe and suction hose from P/S pump.
11) Disconnect suction hose and discharge hose from A/C compressor.
12) For M/T model, remove shift control lever.
13) For A/T model, disconnect A/T select cable from A/T.
14) Remove exhaust No.1 and No.2 pipes.
15) Remove front and rear propeller shafts.
16) Support front suspension frame and engine rear mounting member using jack (2).
17) Carry out Step 1) to 12) of "Removal" under Front Suspension Frame, Stabilizer Bar and/or Bushings Removal and Installation in order to lower engine with front suspension frame.
18) Remove front suspension frame mounting bolts (1).
19) Remove engine rear mounting member bolts (1).
20) Before lowering engine, recheck to make sure all hoses, electric wires and cables are disconnected from engine.
21) Lower engine with transmission, transfer, front suspension frame and engine rear mounting member from engine compartment.
22) Disconnect transmission from engine, referring to Manual Transmission Assembly Dismounting and Remounting or Automatic Transmission Unit Components, if necessary.
23) Remove engine with engine front mounting bracket (1) from engine front mounting (2), if necessary.
24) Remove clutch cover and clutch disk,
referring to Clutch Cover, Clutch Disc and Flywheel Removal and Installation, if necessary.
Installation
1) Install clutch cover and clutch disk.
2) Install engine with engine front mounting bracket to engine front mounting. For tightening torque, referring to Engine Mounting Components, if removed.
NOTE: Be sure to align dowel pin of engine front mounting with dowel hole of engine front mounting bracket.
3) Connect transmission to engine, referring to Manual Transmission Assembly Dismounting and Remounting or Automatic Transmission Unit Components, if removed.
4) Lift engine with transmission, front suspension frame and engine rear mounting member into engine compartment with jack.
5) Tighten engine rear mounting member bolt, referring to Engine Mounting Components.
6) Carry out Step 5) to 19) of "Installation" under Front Suspension Frame, Stabilizer Bar and/or Bushings Removal and Installation in order to lift engine with front suspension frame.
7) Remove engine jack.
8) Install front and rear propeller shafts.
9) Install exhaust No.1 and No.2, referring to Exhaust System Components.
10) Connect suction hose and discharge hose to A/C compressor.
11) Connect high pressure pipe and suction hose from P/S pump.
12) Return disconnected hoses, cables and electric wire.
13) Check all removed parts are back in place.
14) For A/T model, adjust select cable.
15) Refill cooling system with coolant.
16) Refill engine with engine oil.
17) Bleed air from clutch system, referring to Air Bleeding of Brake System for air bleeding procedure.
18) Install battery tray and battery.
19) With engine OFF, turn ignition switch to ON position and check for fuel leakage.
20) Start engine and check coolant, oil and exhaust gas leakage at each connection.