Engine: Service and Repair

REMOVAL
1. Disconnect cable from negative terminal of battery.
2. Drain engine coolant.
3. Remove hood.
4. Remove radiator.
5. (A/T) Disconnect throttle cable and bracket from throttle body.
6. Disconnect accelerator cable from throttle body.

7. Remove cruise control actuator and bracket.

(a) Disconnect the actuator vacuum hose.
(b) Disconnect the actuator connector.
(c) Remove the actuator together with the bracket.

8. Disconnect ground wire from alternator upper bracket.

9. Remove air cleaner assembly, air flow meter and air cleaner hose.

(a) Disconnect the air flow meter connector.
(b) Disconnect the air cleaner cap clips.
(c) Loosen the hose clamp, and remove the air cleaner hose, cap air flow meter assembly.
(d) Remove the air cleaner element.
(e) Remove the three bolts and air cleaner case.

10. Remove igniter.
11. Disconnect heater hoses.
12. Disconnect fuel hoses.

(a) Fuel inlet hose from fuel filter.
(b) Fuel return hose from fuel return pipe.

CAUTION: Catch leaking fuel in a container.

13. Disconnect speedometer cable.

14. (M/T) Remove clutch release cylinder and tube bracket without disconnecting tube.
15. Disconnect transaxle control cable M/T.

16. Remove A/C compressor without disconnecting hoses.

Note: Put aside the compressor, and suspend it to the radiator support with a string.

17. Disconnect wires, connectors and vacuum hoses.

(a) Check connector
(b) Ground straps from LH fender apron
(c) Connectors from relay box
(d) Solenoid resistor connector
(e) Brake booster vacuum hose
(f) A/C idle-up vacuum hoses
(g) Charcoal canister vacuum hose

18. Raise vehicle.

CAUTION: Be sure the vehicle is securely supported.

19. Drain engine oil.
20. Remove engine under covers.

21. Remove suspension lower crossmember.
22. Remove drive shafts.

23. Remove p/s pump without disconnecting hoses.

Note: Put aside the pump and suspend it to the cowl with a string.

24. Disconnect exhaust pipe from catalyst converter.

(a) Loosen the bolt, and disconnect the clamp from the bracket.

(b) Remove the three new nuts, and disconnect the exhaust pipe.

25. Disconnect engine mounting center member.
26. Lower vehicle.
27. Disconnect TCCS ECU connectors.
Disconnect the three connector from the TCCS ECU, and pull out the connectors from the cowl panel.

28. Remove engine and transaxle assembly from vehicle.

(a) Attach the engine hoist chain to the engine hangers.

(b) Remove the through bolt of the RH mounting insulator.
(c) Remove the through bolt, nut, three bolts and LH mounting insulator from the bracket.
(d) Remove the three bolts and LH mounting bracket.

(e) Slowly and carefully lift the engine out of the vehicle. Clear the RH mounting insulator while lowering the transaxle.

CAUTION: Be careful not to hit the P/S gear housing or neutral start switch.

(f) Make sure the engine is clear of all wiring, hoses and cables.
(g) Place the engine and transaxle assembly onto the stand.

29. Remove stiffener plate.

30. (A/T) Remove engine rear end plate.

31. (A/T) Remove torque converter mount bolts.

(a) Turn the crankshaft to gain access to each bolt.
(b) Hold the crankshaft pulley bolt with a wrench, and remove the six bolts.

32. Separate engine and transaxle.

INSTALLATION

1. Assemble engine and transaxle M/T.

2. A/T Install engine and transaxle assembly in vehicle.

(a) Attach the engine hoist chain to the engine hangers.
(b) Lower the engine into the engine compartment. Tilt the transaxle downward, lower the engine and clear the LH mounting.

CAUTION: Be careful not to hit the P/S gear housing or neutral start switch.

(d) Align the RH mounting insulator into the bracket, and temporarily install the through bolt.
(e) Install the LH mounting bracket onto the transaxle case with the three bolts.

Torque: 530 kg-cm (38 ft-lb, 52 Nm)

(f) Install the LH mounting insulator onto the bracket with the three bolts. Align the LH mounting insulator into the body bracket, and temporarily install the mounting insulator through bolt.
(g) Remove the engine hoist chain from the engine.

3. Connect TCCS ECU connectors.
4. Raise vehicle.

CAUTION: Be sure the vehicle is securely supported.

5. Install engine mounting center member.

(a) Install the engine mounting center member with the four bolts. Torque the bolts.

Torque: 400 kg-cm (29 ft-lb, 39 Nm)

(b) Install the front and rear engine mounting insulators with the four nuts and two nuts. Torque the bolts and nuts.

Torque: 440 kg-cm (32 ft-lb, 43 Nm)

6. Connect exhaust pipe to catalyst converter

(a) Place a new gasket on the exhaust pipe.
(b) Connect the exhaust pipe with new three nuts. Torque the nuts.

Torque: 630 kg-cm (46 ft-lb, 62 Nm)

9. Install suspension lower crossmember. Torque the bolts.

Torque:
(A) 2,110 kg-cm (153 ft-lb, 206 Nm)
(B) 400 kg-cm (29 ft-lb, 39 Nm)

10. Install engine under covers.
11. Torque bolts of engine LH and RH mounting insulators.

Torque: 800 kg-cm (58 ft-lb, 78 Nm)

12. Connect vacuum hoses, wires and connectors

(a) Check connector
(b) Ground straps from LH fender apron
(c) Connector from relay box
(d) Solenoid resistor connector
(e) Brake booster vacuum hose
(f) A/C idle-up vacuum hoses
(9) Charcoal canister vacuum hose

13. Install A/C compressor.
14. Connect transaxle control cable.

15. (M/T) Install clutch release cylinder and tube clamp
16. Connect speedometer cable.
17. Connect fuel hoses.

(a) Fuel inlet hose

(b) Fuel return hose

18. Connect heater hoses.

19. Install igniter.

20. Install air cleaner assembly, air flow meter and air cleaner hose.

(a) Install the air cleaner case with the three bolts.
(b) Install the air cleaner element.
(c) Connect the air cleaner hose, and install the air cleaner cap and air flow meter with the four clips.
(d) Connect the air flow meter connector.

21. Connect ground strap to alternator upper bracket.

22. Install cruise control actuator and bracket.

(a) Install the actuator and bracket.
(b) Connect the actuator connector.
(c) Connect the actuator vacuum hoses.

23. (A/T) Install throttle cable, and adjust it.
24. Install accelerator cable, and adjust it.
25. Install radiator.
26. Install battery.

27. Fill with engine coolant

capacity (w/ heater):
6.4 liters (6.8 US qts, 5.6 Imp. qts)

28. Fill with engine oil

Capacity:
Drain and refill
w/o oil filter change
143.7 liters (3.9 US qts, 3.3 Imp. qts)
w/ Oil filter change
4.1 liters (4.3 US qts, 3.6 Imp. qts)
Dry fill 4.5 liters (4.8 US qts, 4.0 Imp. qts)

29. Start engine and check for leaks
30. Perform engine adjustment

(a) Adjust the drive belt.
Drive belt tension:

Alternator
w/ Air con. New belt 175 +/- 5 lb
Used belt 13O +/- 1O lb
w/o Air con. New belt 125 +/- 25 lb
Used belt 95 +/- 20 lb

P/S pump 125 +/- 1O lb
Used belt 80 +/- 20 lb

(b) Adjust the ignition timing.

Ignition timing: 10 ° BTDC @ idle (w/ Terminals T and E1 short-circuited)

(c) Adjust the valve clearance.

Valve clearance:
Intake 0.19-0.29 mm (0.007-0.011 in.)
Exhaust 0.28-0.38 mm (0.011 -0.015 in.)

31. Install hood.
32. Check toe-in.
33. Perform road test.
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
34. Recheck engine coolant and engine oil levels.