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 after disconnecting windshield washer hose.





4. Drain cooling system.

WARNING: To help avoid danger of being burned, do not remove drain plug and radiator cap while engine and radiator are still hot. Scalding fluid and steam can be blown out under pressure if plug and cap are taken off too soon.

5. Remove radiator with cooling fan.





6. Remove air cleaner outlet hose.
7. Remove air cleaner case by removing its fastening bolts.





8. Disconnect the following cables.
- Accelerator cable from throttle body
- Shift and select cable from transmission (M/T)
- Clutch cable from transmission (M/T)
- Gear select cable from transmission (A/T)
9. Remove accelerator cable from bracket.





10. Disconnect the following hoses:
- Brake booster hose from intake manifold
- Coolant hoses from throttle body
- Fuel feed hose from delivery pipe
- Fuel return hose from return pipe
- Heater hose from water outlet cap
- Radiator inlet hose from water outlet cap
- Vacuum hose from EVAP canister purge valve
11. Disconnect the following electric wires:
- Injector wire
- CMP sensor coupler
- Ignition coil wire
- TP sensor coupler
- MAP sensor coupler
- IAC valve coupler
- MDP sensor coupler
- Crankshaft position sensor coupler
- Ground terminals from cylinder head and intake manifold
- EVAP canister purge valve coupler
- EGR valve coupler
- Heated oxygen sensor-1 wire
- ECT sensor coupler
- Generator wires
- Starter wires
- Oil pressure switch wire
- Power steering pressure switch coupler
- A/C magnetic switch wire
- Back-up light switch (M/T)
- Vehicle speed sensor
- Battery negative cable from transmission
- Transmission range switch (A/T)
- Forward clutch revolution sensor (A/T)
Release above wire harness from clamps.





12. Remove clutch operating cylinder from transmission with hose still attached (M/T).

NOTE: Suspend removed clutch operating cylinder at a place free from any possible damage during removal and installation of engine assembly.

13. Remove right and left engine under covers.





14. Remove exhaust No. 1 pipe.
15. Drain engine and transmission oil.
16. Remove drive shaft joints from differential gear of transmission and center bearing support.
For engine and transmission removal, it is not necessary to remove drive shafts from steering knuckle.
17. Remove A/C compressor from compressor bracket with hoses still attached.

NOTE: Suspend removed compressor at a place free from any possible damage during removal and installation of engine assembly.

18. Install lifting device.





19. Remove mounting member from front member and suspension frame.
20. Remove engine left mounting from body.
21. Remove engine right mounting from right mounting bracket.
22. Remove P/S pump from bracket.

NOTE: Suspend removed P/S pump at a place free from any possible damage during removal and installation of engine assembly.

23. Before removing engine with transmission from body, recheck to make sure all hoses, electric wires and cables are disconnected from engine and transmission.





24. Lower engine with transmission from body.

NOTE: Before lowering engine, to avoid damage to A/C compressor, raise it through clearance made on engine crankshaft pulley side. At this time, use care so that no excessive force is applied to hoses.

25. Disconnect transmission from engine.
26. Remove clutch cover and clutch disk.

INSTALLATION
1. Install clutch cover and clutch disk.
2. Connect transmission to engine.
3. Lift engine with transmission into engine compartment, but do not remove lifting device.





4. Install engine right mounting to right mounting bracket and stiffener.
5. Install engine left mounting to body.
6. Install mounting member to front member and suspension frame.
7. Tighten bolts and nuts of all parts installed in above steps 4), 5) and 6) to specified torque.
Tightening Torque
(a): 55 Nm (5.5 kg-m, 40.0 ft. lbs.)
(b): 45 Nm (4.5 kg-m, 32.5 ft. lbs.)
8. Remove lifting device.
9. Reverse removal procedures for installation of remainder.
- Push in each drive shaft joint fully so that snap ring engages with differential gear or center bearing support. Use care not to damage oil seal lip when inserting.
- Clamp electric wire securely.
10. Adjust gear shift control cable.
11. Refill transmission with gear oil.
12. Refill engine with engine oil.
13. Refill cooling system.
14. Upon completion of installation, check to make sure that there is no fuel leakage, coolant leakage, transmission oil leakage or exhaust gas leakage at each connection.
15. Adjust accelerator cable play.