Engine: Service and Repair

REMOVAL
1. REMOVE HOOD
2. REMOVE OUTER FR COWL TOP PANEL ASSEMBLY
a. Remove the 2 wiper arm head caps.
b. Remove the 2 nuts and wiper arm and blade assemblies.
c. Remove the head to cowl top seal.
d. Remove the cowl panel hole cover.
e. Remove the clip and disconnect the window washer hose, and remove the cowl top ventilator louver. Remove the RH and LH ventilator louvers.
f. Remove the 11 bolts and disconnect the wiper motor connector, and remove the cowl top ventilator louver.
3. REMOVE HEATER AIR DUCT
4. REMOVE BATTERY AND TRAY
5. DRAIN ENGINE COOLANT
6. DRAIN ENGINE OIL
7. REMOVE V-BANK COVER
8. REMOVE AIR CLEANER CAP ASSEMBLY AND AIR CLEANER CASE
9. REMOVE CRUISE CONTROL ACTUATOR
10. REMOVE RADIATOR
11. DISCONNECT A/T OIL COOLER PIPE
a. Disconnect the A/T oil cooler hose from the A/T oil cooler pipe.
b. Remove the bolt and disconnect the A/T oil cooler pipe from the frame.
12. DISCONNECT CONNECTORS, CLAMP AND HOSES
a. Disconnect the noise filter connector.
b. Disconnect the generator wire and connector.
c. Disconnect the starter wire and connector.
d. Disconnect the 2 ground strap connectors from RH fender apron.
e. Disconnect the ground strap from LH fender apron.
f. Disconnect the brake booster vacuum hose from air intake chamber.
g. Disconnect the engine coolant reservoir hose from water outlet.
h. Disconnect the heater hose from intake manifold.
i. Disconnect the heater hose from water inlet housing.
j. Disconnect the fuel inlet hose from fuel pipe.
k. Disconnect the EVAP hose from pipe on emission control valve set.
l. Disconnect the 2 vacuum hoses from vacuum tank for ACIS.





13. DISCONNECT ENGINE WIRE FROM CABIN
a. Remove the ECM.
b. Disconnect the grommet from the cowl panel, and pull out the engine wire.





14. DISCONNECT A/C COMPRESSOR FROM ENGINE
a. Disconnect the A/C compressor connector.
b. Remove the drive belt.
c. Remove the 4 bolts, nut and drive belt adjusting bar bracket.
d. Disconnect the A/C compressor from the engine.
15. DISCONNECT A/T SHIFT CONTROL CABLE FROM TRANSAXLE





16. REMOVE FRONT EXHAUST PIPE
a. Remove the 2 bolts holding the support stay to the support bracket.
b. Remove the 2 bolts and 2 compression springs holding the front exhaust pipe to the center exhaust pipe.
c. Remove the 4 nuts holding the front exhaust pipe to the exhaust manifolds.
d. Remove the front exhaust pipe and 3 gaskets.
17. REMOVE FENDER APRON SEALS
18. REMOVE DRIVE SHAFTS
19. DISCONNECT STABILIZER BAR LINKS
20. DISCONNECT INTERMEDIATE SHAFT ASSEMBLY





21. DISCONNECT PS HOSE FROM PS OIL RESERVOIR





22. DISCONNECT PS HOSE FROM PS RESERVOIR PIPE
23. REMOVE ENGINE UNDER COVER
24. DISCONNECT FENDER APRON SEALS
Remove the screws and turn over the front side of the LH and RH fender liners.





25. ATTACH ENGINE SLING DEVICE TO ENGINE HANGERS
a. Install the NO. 2 engine hanger in the correct direction.
Part No.:
NO. 2 engine hanger 12282-20020
Bolt 91642-80825
Torque: 19.5 Nm (200 kgf-cm, 14 ft. lbs.)
b. Attach the sling device to the engine hangers.

CAUTION: Do not attempt to hang the engine by hooking the chain to any other part.





26. REMOVE RH ENGINE MOUNTING STAY
Remove the 3 bolts and RH engine mounting stay.





27. REMOVE ENGINE MOVING CONTROL ROD AND NO. 2 RH ENGINE MOUNTING BRACKET
Remove the 3 bolts, control rod and mounting bracket.





28. REMOVE LOWER BRACES
Remove the 6 bolts, 4 nuts and 4 lower braces.





29. REMOVE ENGINE, TRANSAXLE AND FRONT SUSPENSION MEMBER ASSEMBLY FROM VEHICLE
Lower the engine out of the vehicle slowly and carefully.

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





30. DISCONNECT PS VANE PUMP FROM ENGINE
a. Disconnect the PS oil pressure switch connector.
b. Disconnect the heated oxygen sensor (bank 1 sensor 1) connector clamp.
c. Remove the nut, and disconnect the PS pressure tube from the NO. 1 engine hanger.
d. Loosen the 2 bolts, and remove the drive belt.
e. Remove the 2 bolts, and disconnect the PS vane pump from the engine.
31. REMOVE FRONT SUSPENSION MEMBER





a. Remove the 4 bolts holding the transaxle to the LH engine mounting insulator.





b. Remove the 4 bolts and engine mounting absorber.





c. Remove the 3 bolts holding the front engine mounting insulator to the front frame.
d. Remove the 2 hole plugs.





e. Remove the 4 nuts holding the rear engine mounting insulator to the front frame.
f. Remove the front suspension member.





32. REMOVE FRONT ENGINE MOUNTING INSULATOR FROM ENGINE
Remove the 4 bolts and mounting insulator.





33. REMOVE REAR ENGINE MOUNTING INSULATOR FROM ENGINE
Remove the 4 bolts, the mounting insulator and bracket assembly.
34. REMOVE STARTER
35. DISCONNECT ENGINE WIRE FROM TRANSAXLE
a. Disconnect the PNP switch connector.
b. Disconnect the solenoid connector.
c. Disconnect the ATF temperature sensor connector.





36. REMOVE TORQUE CONVERTER CLUTCH MOUNTING BOLTS
a. Remove the 2 bolts, exhaust pipe support stay and flywheel housing under cover.
b. Turn the crankshaft pulley bolt to gain access to each bolt.
c. Hold the crankshaft pulley bolt with a wrench, and remove the 6 bolts.





37. REMOVE TRANSAXLE
a. Remove the bolt, nut and LH exhaust manifold stay.
b. Remove the 8 bolts and ground strap.
c. Remove the transaxle together with the torque converter clutch from the engine.





38. REMOVE DRIVE PLATE
Remove the 8 bolts, rear plate, drive plate and front spacer.

INSTALLATION
1. INSTALL DRIVE PLATE





a. Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent

Sequence:

b. Install the front spacer, drive plate and rear plate on the crankshaft.
c. Install and uniformly tighten the 8 bolts in several passes, in the sequence shown.
Torque: 83 Nm (850 kgf-cm, 61 ft. lbs.)





2. INSTALL TRANSAXLE TO ENGINE
a. Attach the transaxle to the engine.
b. Install the ground strap and 8 bolts.
Torque:
A bolt: 48 Nm (490 kgf-cm, 35 ft. lbs.)
B bolt: 37 Nm (380 kgf-cm, 48 ft. lbs.)
Other bolt: 66 Nm (670 kgf-cm, 48 ft. lbs.)
c. Install the LH exhaust manifold stay with the bolt and nut.
Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.)
3. INSTALL TORQUE CONVERTER CLUTCH BOLTS





a. Apply adhesive to 2 or 3 threads of the bolt.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent





b. Hold the crankshaft pulley bolt with a wrench, and install the 6 bolts evenly.
Torque: 41 Nm (420 kgf-cm, 30 ft. lbs.)

HINT: First install the dark green colored bolt, then install the other bolts.

c. Install the flywheel housing under cover and exhaust pipe support stay with the 2 bolts.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)
4. CONNECT ENGINE WIRE TO TRANSAXLE
a. Connect the PNP switch connector
b. Connect the solenoid connector
c. Connect the ATF temperature sensor connector
5. INSTALL STARTER
6. CONNECT THROTTLE CABLE TO THROTTLE BODY
7. INSTALL REAR ENGINE MOUNTING INSULATOR
Install the mounting insulator with the 4 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
8. INSTALL FRONT ENGINE MOUNTING INSULATOR
Install the mounting insulator with the 4 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
9. INSTALL FRONT SUSPENSION MEMBER





a. Connect the rear engine mounting insulator with the 4 nuts.
Torque: 66 Nm (670 kgf-cm, 48 ft. lbs.)
b. Install the 2 hole plugs.





c. Connect the front engine mounting insulator with the 3 bolts.
Torque:
Green color bolt: 66 Nm (670 kgf-cm, 48 ft. lbs.)
Silver color bolt: 44 Nm (450 kgf-cm, 32 ft. lbs.)





d. Install the engine mounting absorber with the 4 bolts.
Torque: 48 Nm (490 kgf-cm, 35 ft. lbs.)





e. Connect the LH engine mounting insulator with the 4 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)





10. INSTALL PS VANE PUMP
a. Install the PS vane pump with the 2 bolts.
Torque: 43 Nm (440 kgf-cm, 31 ft. lbs.)
b. Install the drive belt.
c. Connect the PS pressure tube with the nut.
d. Connect the heated oxygen sensor (bank 1 sensor 1) connector clamp.
e. Connect the PS oil pressure switch connector.





11. INSTALL ENGINE TRANSAXLE AND FRONT SUSPENSION MEMBER ASSEMBLY IN VEHICLE
a. Attach the engine sling device to the engine hangers.
b. Lift the engine into the engine compartment.





12. INSTALL LOWER BRACES
Install the 4 lower braces with the 6 bolts and 4 nuts.
Torque:
Bolt A: 181 Nm (1,850 kgf-cm, 134 ft. lbs.)
Bolt B: 32 Nm (330 kgf-cm, 24 ft. lbs.)
Nut C: 36 Nm (370 kgf-cm, 27 ft. lbs.)





13. INSTALL NO. 2 ENGINE MOUNTING BRACKET AND ENGINE MOVING CONTROL ROD
Install the NO. 2 engine mounting bracket and mounting moving control rod with the 3 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)





14. INSTALL RH ENGINE MOUNTING STAY
Install the RH mounting stay with the 3 bolts.
Torque: 32 Nm (320 kgf-cm, 23 ft. lbs.)
15. REMOVE ENGINE SLING DEVICE
16. CONNECT FENDER APRON SEALS
17. INSTALL ENGINE UNDER COVER





18. CONNECT PS HOSE TO PS RESERVOIR PIPE





19. CONNECT PS HOSE TO PS OIL RESERVOIR
20. CONNECT INTERMEDIATE SHAFT ASSEMBLY
21. INSTALL DRIVE SHAFTS
22. CONNECT STABILIZER BAR LINK
23. INSTALL ENGINE FENDER APRON SEALS





24. INSTALL FRONT EXHAUST PIPE
a. Temporarily install 3 new gaskets and the front exhaust pipe with the 2 bolts, 2 compression springs and 4 nuts.
b. Tighten the 4 nuts holding the exhaust manifolds to the front exhaust pipe.
Torque: 62 Nm (630 kgf-cm, 46 ft. lbs.)
c. Tighten the 2 bolts and 2 compression springs holding the front exhaust pipe to the center exhaust pipe.
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)
d. Install the support stay with the 2 bolts.
Torque: 33 Nm (330 kgf-cm, 24 ft. lbs.)
25. CONNECT A/T SHIFT CONTROL CABLE TO TRANSAXLE
26. INSTALL A/C COMPRESSOR





a. Install the A/C compressor and drive belt adjusting bar bracket with the 4 bolts and nut.
Torque:
Bolt A: 25 Nm (250 kgf-cm, 18 ft. lbs.)
Bolt B: 18 Nm (185 kgf-cm, 13 ft. lbs.)
Nut C: 25 Nm (250 kgf-cm, 18 ft. lbs.)
b. Install the drive belt.





c. Connect the A/C compressor connector.
27. CONNECT ENGINE WIRE TO CABIN
a. Push in the engine wire through the cowl panel. Install the grommet.
b. Install the ECM.
28. CONNECT CONNECTORS, CLAMP AND HOSES
a. Connect the noise filter connector on cowl panel.
b. Connect the generator connector and wire.
c. Connect the starter connector and wire.
d. Connect the 2 ground strap connectors to RH fender apron.
e. Connect the ground strap to LH fender apron.
f. Connect the brake booster vacuum hose to air intake chamber.
g. Connect the engine coolant reservoir hose to water outlet.
h. Connect the heater hose to intake manifold.
i. Connect the heater hose to water inlet housing.
j. Connect the fuel inlet hose to fuel pipe.
k. Connect the EVAP hose to pipe on emission control valve set.
l. Connect the 2 vacuum hoses to vacuum tank for ACIS.
29. CONNECT A/T OIL COOLER PIPE
a. Install the A/T oil cooler pipe to the frame with the bolt.
b. Connect the A/T oil cooler hose to the A/T oil cooler pipe.
30. INSTALL RADIATOR
31. INSTALL CRUISE CONTROL ACTUATOR
32. INSTALL CHARCOAL CANISTER
33. INSTALL AIR CLEANER CAP ASSEMBLY AND AIR CLEANER CASE
34. INSTALL BATTERY TRAY AND BATTERY
35. INSTALL HEATER AIR DUCT
36. INSTALL OUTER FR COWL TOP PANEL ASSEMBLY
a. Connect the wiper motor connector and install the cowl top ventilator louver with the 11 bolts.
b. Connect the window washer hose, and install the cowl top ventilator louver with clip. Install the RH and LH ventilator louvers.
c. Install the cowl panel hole cover.
d. Install the head to cowl panel top seal.
e. Install the wiper arm and blade assemblies with the 2 nuts.
Torque: 20.5 Nm (205 kgf-cm, 15 ft. lbs.)
f. Install the 2 wiper arm head caps.
37. INSTALL HOOD
38. INSTALL V-BANK COVER
39. FILL ENGINE WITH OIL
40. FILL WITH ENGINE COOLANT
41. BLEED POWER STEERING SYSTEM
42. START ENGINE AND CHECK FOR LEAKS
43. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
44. RECHECK ENGINE COOLANT AND OIL LEVELS