Engine: Service and Repair

REMOVAL
1. REMOVE TRANSMISSION
2. REMOVE ENGINE UNDER COVER
3. DRAIN ENGINE COOLANT
4. DRAIN ENGINE OIL
5. REMOVE HOOD
6. REMOVE RADIATOR
7. REMOVE DRIVE BELT FOR GENERATOR, FAN WITH FLUID COUPLING AND WATER PUMP PULLEY
8. DISCONNECT THESE CABLES:
a) Disconnect the accelerator cable from the throttle body.
b) w/ Cruise Control System:
Remove the actuator cover, and disconnect the cruise control cable from the actuator.





9. REMOVE AIR CLEANER ASSEMBLY
a) Disconnect the MAF meter connector.
b) Disconnect the 3 wire clamps and engine wire.
c) Disconnect the air hose from the air cleaner cap.
d) Loosen the air cleaner hose clamp.
e) Remove the 3 bolts and the MAF meter, resonator and air cleaner assembly.
10. REMOVE INTAKE AIR CONNECTOR





11. (w/ A/C)
DISCONNECT A/C COMPRESSOR
a) Loosen the idler pulley nut and adjusting bolt, and remove the drive belt.
b) Disconnect the A/C compressor connector.
c) Remove the 4 bolts, and disconnect the compressor from the bracket.

HINT: Put aside the compressor, and suspend it.





12. REMOVE GENERATOR WIRE
a) Disconnect the generator connector.
b) Remove the nut, and disconnect the generator wire and wire clip.





13. DISCONNECT HEATER HOSES
a) Remove the bolt and hose clamp.
b) Disconnect the heater hoses.





14. DISCONNECT HOSES
Disconnect these hoses:
(1) Brake booster vacuum hose
(2) EVAP hose
(3) 2 air hoses for PS idle-up
(4) w/ A.D.D. Vacuum hose
(5) Fuel return hose
(6) Fuel inlet hose
15. DISCONNECT PS PUMP FROM ENGINE
16. DISCONNECT ENGINE WIRE FROM CABIN





a) Remove these parts:
(1) Glove compartment door
(2) Lower finish No.2 panel
b) Disconnect the 4 ECM connectors.
c) Disconnect the 2 cassette connectors (cowl wire x engine wire) and 2 wire clamps from the lower finish panel.





d) Disconnect these connectors ground strap and clamps:
(1) VSV connector for EVAP and clamp
(2) Ground strap from cowl top panel
(3) 2 engine wire clamps
e) Disconnect the vapor pressure sensor connector.
f) Disconnect the VSV connector for vapor pressure sensor.





g) Remove the bolt and wire bracket.
h) Remove 2 nuts holding the engine wire retainer to the cowl panel, and pull out the engine wire from the cabin.
17. REMOVE ENGINE FROM VEHICLE





a) Install a rear engine hanger in the correct direction.
Part No.:
Engine hanger NO.2 12282-75020
Bolt 91512-61020
Torque: 42 Nm (420 kgf-cm, 30 ft. lbs.)
b) Attach the engine hoist chain to the 2 engine hangers.





c) Remove the 4 bolts and nuts holding the engine front mounting insulators to the frame.
d) Lift the engine out of the vehicle slowly and carefully.

NOTICE: Make sure the engine is clear of all wiring and hoses.

e) Place the engine onto the stand.

INSTALLATION
1. INSTALL ENGINE ASSEMBLY IN VEHICLE
a) Attach the engine hoist chain to the engine hangers.
b) Lower the engine into the engine compartment.
c) Keep the engine level, and align the RH and LH mountings and body mountings.
d) Attach the RH and LH mounting insulators to the body mountings, and temporarily install the 4 bolts and nuts.
e) Remove the hoist chain.
f) Remove the bolt and rear engine hanger.





2. TIGHTEN RH AND LH ENGINE MOUNTING INSULATOR BOLTS AND NUTS
Tighten the 4 bolts and nuts holding the mounting insulators to the body mountings.
Torque: 38 Nm (387 kgf-cm, 28 ft. lbs.)
3. CONNECT ENGINE WIRE TO CABIN
4. CONNECT GENERATOR WIRE
5. CONNECT PS PUMP
6. CONNECT HOSES
Connect these hoses:
- Fuel return hose
- Fuel inlet hose
- w/ A.D.D.
Vacuum hose
- Brake booster vacuum hose
- EVAP hose
- 2 air hoses for PS idle-up
7. CONNECT HEATER HOSES
8. (w/ A/C)
INSTALL A/C COMPRESSOR
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
9. INSTALL INTAKE AIR CONNECTOR
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
10. INSTALL AIR CLEANER ASSEMBLY
11. CONNECT THESE CABLES
a) Connect the throttle cable to the throttle body.
b) w/ Cruise Control System:
Connect the cruise control cable to the actuator, and install the actuator cover.
12. INSTALL RADIATOR
13. FILL WITH ENGINE OIL
14. FILL WITH ENGINE COOLANT
15. INSTALL TRANSMISSION