Engine: Service and Repair
Engine Assembly Removal and InstallationRemoval
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 (1) 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 cooling fan assembly and radiator.
6) Remove air cleaner outlet hose (1).
7) Remove air cleaner case assembly (2) by removing its fastening bolts.
8) Remove engine cover.
9) Disconnect the cables.
^ Accelerator cable (1) from throttle body
^ Shift and select cable from transmission (M/T)
^ Gear select cable from transmission (A/T)
10) Remove accelerator cable with its bracket from intake manifold.
11) Disconnect the hoses:
Brake booster hose from intake manifold
Heater outlet hose from heater outlet pipe
Fuel feed hose from delivery pipe
Vacuum hose from EVAP canister purge valve
Fuel return hose from return pipe
P/S suction hose and high pressure pipe from P/S pump
Heater inlet hose from water outlet cap
12) Disconnect the electric wires:
Injector wire (1)
Starter wires
CMP sensor coupler (2)
Knock sensor coupler (13)
Ignition coil wire (3)
Oil pressure switch wire (14)
TP sensor coupler (4)
Cylinder block heater connector (if equipped)
MAF sensor coupler (5)
Power steering pressure switch coupler
IAC valve coupler (6)
A/C magnetic switch wire (if equipped)
MAP sensor coupler (7)
Back-up light switch (M/T)
CKP sensor coupler (8)
Vehicle speed sensor (15)
Ground terminals from cylinder head and intake manifold (9)
Input shaft speed sensor (16)
EVAP canister purge valve coupler (10)
Output shaft speed sensor (17)
EGR valve coupler (11)
Battery negative cable from transmission (18)
Heated oxygen sensor-1 wire
Transmission range switch (19) (A/T)
ECT sensor coupler (12)
Valve body connector (20) (A/T)
Generator wires
Release the wire harness from clamps.
13) 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.
14) Remove right and left engine under covers.
15) Remove generator belt for equipped with A/C.
16) Remove exhaust manifold cover.
17) Remove exhaust No.1 pipe and No. 2 pipe.
18) Drain engine oil, transaxle oil for M/T vehicle or A/T fluid for A/T vehicle and transfer oil for 4WD vehicle.
19) Remove drive shafts.
20) Separate propeller shaft front end from transfer output flange for 4WD vehicle.
21) Remove A/C compressor from compressor bracket with hoses still attached, if equipped with A/C.
NOTE: Suspend removed compressor at a place free from any possible damage during removal and installation of engine assembly.
22) Remove intake manifold rear stiffener.
23) Install lifting device.
24) Remove mounting member (1) from front member and suspension frame (7) for 2WD vehicle.
25) Remove suspension frame (7) with stabilizer bar and suspension control arms for 4WD vehicle.
26) Remove engine left mounting bolts (9).
27) Remove engine right mounting No. 1 bracket (8).
28) Before removing engine with transaxle and transfer (for 4WD vehicle) from vehicle body, recheck to make sure all hoses, electric wires and cables are disconnected from engine and transaxle.
29) Lower engine with transaxle and transfer (for 4WD vehicle) from vehicle 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.
30) Disconnect transfer from transaxle.
31) Disconnect transaxle from engine.
32) Remove clutch cover and clutch disk.
Installation
1) Install clutch cover and clutch disk.
2) Connect transaxle to engine.
3) Connect transfer to transaxle
4) Lift engine with transaxle and transfer (for 4WD vehicle) into engine compartment, but do not remove lifting device.
5) Install engine right mounting No. 1 bracket (8) to right mounting bracket (4), generator & P/S bracket and engine right mounting (3).
6) Install engine left mounting bolts (9).
7) Install mounting member (1) to front member and suspension frame (7) for 2WD vehicle.
8) Install suspension frame (7) with stabilizer bar and suspension control arms for 4WD vehicle.
9) Tighten bolts and nuts of all parts installed in steps 5), 6) and 7) to specified torque.
Tightening torque
Engine mounting bolts and nuts (a): 55 Nm (5.5 kgf-cm, 40.0 ft. lbs.)
Engine front and rear mounting nuts (b): 45 Nm (4.5 kgf-cm, 32.5 ft. lbs.)
10) Remove lifting device.
11) Reverse removal procedures for installation of reminder.
^ 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.
12) For 4WD vehicle, connect propeller shaft.
13) Adjust gear shift control cable
14) Install generator belt.
15) Refill transaxle with A/T fluid or gear oil.
16) For 4WD vehicle, refill transfer with transfer oil.
17) Refill engine with engine oil.
18) Refill cooling system.
19) Upon completion of installation, check to make sure that there is no fuel leakage, coolant leakage, transaxle oil leakage, transfer oil leakage or exhaust gas leakage at each connection.
20) Adjust accelerator cable play.