Engine: Service and Repair
REMOVAL
1. REPLACE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT AND OIL
3. DRAIN TRANSMISSION OIL
4. REMOVE HOOD
5. REMOVE RADIATOR ASSEMBLY
6. DISCONNECT HEATER HOSES
7. REMOVE FAN WITH FLUID COUPLING AND FAN PULLEYS
8. REMOVE AIR CLEANER ASSEMBLY
9. DISCONNECT CABLES
a. Disconnect the accelerator cable.
b. A/T: Disconnect the throttle cable.
c. w/ Cruise Control: Disconnect the cruise control actuator cable.
10. DISCONNECT HOSES
a. Disconnect the brake booster vacuum hose.
b. Disconnect the EVAP hose.
c. Disconnect the fuel return hose.
d. Disconnect the fuel inlet hose.
11. DISCONNECT STARTER WIRE AND CONNECTOR
a. Remove the bolt, and disconnect the ground strap.
b. Remove the 2 nuts, disconnect the positive (+) terminal cable from the battery.
c. Disconnect the 2 starter wire clamps and connector.
d. Remove the nut, and disconnect the wire from the relay block No.2.
12. DISCONNECT GENERATOR WIRE
13. DISCONNECT ENGINE WIRE FROM CABIN
a. Remove the glove compartment.
b. Remove the lower finish No.2 panel.
c. Remove the 2 bolts and ECM.
d. Disconnect the 4 ECM connectors.
e. Disconnect the VSV connector for the EVAP.
f. Disconnect the vapor pressure sensor connector and clamp.
g. Disconnect the VSV connector for the vapor pressure sensor.
h. Disconnect the igniter connector.
i. Disconnect the ground strap.
j. Remove the bolt and 2 nuts.
k. Pull out the engine wire from the cabin.
14. M/T: REMOVE SHIFT LEVER ASSEMBLY
a. Remove the shift lever knob.
b. Remove the 4 screws and shift lever boot.
c. Remove the 6 bolts, shift lever assembly and gasket.
15. REMOVE PROPELLER SHAFT
16. DISCONNECT SPEEDOMETER CABLE
NOTICE: Do not lose the felt protector and washers.
17. 2WD, 4WD:NO.1 EXHAUST PIPE WITH TWC
18. M/T: REMOVE CLUTCH RELEASE CYLINDER
Remove the 2 bolts, and disconnect the clutch release cylinder.
19. PLACE JACK UNDER TRANSMISSION
20. REMOVE ENGINE REAR MOUNTING BRACKET
Remove the 8 bolts holding the mounting bracket to the mounting insulator and crossmember.
21. REMOVE ENGINE WITH TRANSMISSION
a. w/ A/C: Remove the bolt and disconnect the A/C compressor wire clamp.
b. Install a No.2 engine hanger in the correct direction.
Part No.:
Torque: 40 Nm (400 kgf-cm, 30 ft. lbs.)
c. Attach the engine hoist chain to the 2 engine hangers.
d. Remove the 4 bolts and 4 nuts Holding the engine front mounting insulators to the frame.
e. Lift the engine with transmission out of the vehicle slowly and carefully.
NOTICE: Make sure the engine is clear of all wiring and hoses.
f. Place the engine and transmission assembly onto the stand.
22. SEPARATE ENGINE AND TRANSMISSION
INSTALLATION
1. INSTALL TRANSMISSION TO ENGINE
2. INSTALL ENGINE AND TRANSMISSION ASSEMBLY IN VEHICLE
a. Attach the engine hoist chain to the engine hangers.
b. Lower the engine and transmission assembly 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. Jack up and put the transmission onto the frame.
f. Remove the engine chain hoist from the engine.
g. Remove the 2 bolts and No.2 engine hanger.
h. Connect the A/C compressor wire with the bolt.
3. INSTALL ENGINE REAR MOUNTING BRACKET
a. Raise the transmission slightly by raising the engine with a jack and a wooden block under the transmission.
b. Install the engine rear mounting bracket to the frame.
Torque: 58 Nm (590 kgf-cm, 43 ft. lbs.)
c. Lower the transmission and rest it on the extension housing.
d. Install the mounting bracket to the mounting insulator.
Torque: 18 Nm (183 kgf-cm, 13 ft. lbs.)
4. TIGHTEN RH AND LH ENGINE MOUNTING INSULATOR BOLTS AND NUTS
Tighten the 4 bolts and 4 nuts holding the mounting insulators to the body mountings
Torque: 38 Nm (387 kgf-cm, 28 ft. lbs.)
5. M/T: INSTALL CLUTCH RELEASE CYLINDER
Install the clutch release cylinder with the 2 bolts.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
6. 2WD, 4WD: INSTALL NO.1 EXHAUST PIPE WITH TWC
7. CONNECT SPEEDOMETER CABLE
8. INSTALL PROPELLER SHAFT
9. M/T: INSTALL SHIFT LEVER ASSEMBLY
a. Install a new gasket and shift lever assembly with the 6 bolts.
b. Install shift lever boot with the 4 screws.
c. Install the shift lever knob.
10. CONNECT ENGINE WIRE TO CABIN
a. Push in the engine wire through the cowl panel.
b. Install the bolt and 2 nuts.
c. Connect the ground strap.
d. Connect the igniter connector.
e. Connect the VSV connector for the EVAP.
f. Connect the vapor pressure sensor connector and clamp.
g. Connect the VSV connector for the vapor pressure sensor.
h. Connect the 4 ECM connectors to the ECM.
i. Install the ECM with the 2 bolts.
j. Install the lower finish No.2 panel.
k. Install the glove compartment.
11. CONNECT GENERATOR WIRE
12. CONNECT STARTER WIRE AND CONNECTOR
a. Connect the 2 starter wire clamps and connector.
b. Install the 2 nuts, and connect the positive (+) terminal cable to the battery.
c. Connect the ground strap with the bolt.
d. Connect the wire from the relay block No.2 with the nut.
13. CONNECT HOSES
a. Connect the fuel return hose.
b. Connect the fuel inlet hose.
c. Connect the brake booster vacuum hose.
d. Connect the EVAP HOSE.
14. CONNECT HEATER HOSES
15. CONNECT CABLES
a. Connect the accelerator cable.
b. A/T: Connect the throttle cable.
c. w/ Cruise Control: Connect the cruise control actuator cable.
16. INSTALL FAN WITH FLUID COUPLING AND FAN PULLEYS
17. INSTALL RADIATOR ASSEMBLY
18. INSTALL AIR CLEANER ASSEMBLY
19. FILL WITH ENGINE OIL AND COOLANT
20. FILL TRANSMISSION OIL
21. START ENGINE AND CHECK FOR LEAKS
22. CHECK IGNITION TIMING
23. INSTALL ENGINE UNDER COVER
24. INSTALL HOOD
25. ROAD TEST VEHICLE
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
26. RECHECK ENGINE COOLANT AND ENGINE OIL LEVELS