Cylinder Block Assembly: Service and Repair

CYLINDER BLOCK
COMPONENTS

REMOVAL OF ENGINE (4A-FE)
1. REMOVE BATTERY AND HOOD
2. REMOVE RH AND LH ENGINE UNDER COVERS
3. DRAIN ENGINE OIL
4. DRAIN ENGINE COOLANT
5. DRAIN GEAR OIL (M/T) OR FLUID (A/T)
6. REMOVE RADIATOR WITH COOLING FAN
7. DISCONNECT ACCELERATOR WIRE FROM BRACKET
8. (A/T) DISCONNECT THROTTLE CABLE FROM BRACKET
9. (w/ CRUISE CONTROL) REMOVE CRUISE CONTROL ACTUATOR

10. REMOVE AIR CLEANER ASSEMBLY
(a) Disconnect the vacuum hose from the charcoal canister.
(b) Disconnect the air intake temp. sensor connector from the air cleaner cap.
(c) Disconnect the air hose from the air pipe.
(d) Loosen the air cleaner hose clamp bolt.
(e) Disconnect the air cleaner cap clips.
(f) Remove the air cleaner cap with air cleaner hose.
(g) Remove the air cleaner filter element.

(h) Disconnect the harness clamp from the boss, and remove the three bolts and air cleaner case.
(i) Remove the two bolts and air cleaner support bracket.
11. REMOVE WASHER TANK

12. DISCONNECT FOLLOWING HOSES:
(a) Disconnect the following vacuum hoses from the intake chamber:
(1) Vacuum sensor hose from gas filter
(2) Brake booster vacuum hose
(3) (with A/C), Two A/C vacuum hoses from actuator
(b) (w/PS and/or with A/C) Disconnect the air hose from the air pipe.
(c) Disconnect the fuel return hose from the air pipe.
13. DISCONNECT ENGINE WIRE
(a) Remove the three nuts, No.2 junction block and No.5 relay block.
(b) Disconnect the following connectors:
- Ground strap connector and bolt
- Check connector
- Vacuum sensor connector
- (with A/C) A/C wire connector
(c) Remove the front and rear console boxes.

(d) Remove the center cover in front of the console box.
(e) Disconnect the four connectors from the cowl wire and ECU.

(f) Pull out the engine wire from the cowl panel.

14. DISCONNECT HEATER WATER HOSES
(a) Disconnect the heater hose from the water inlet housing.
(b) Disconnect the hose from the water inlet pipe.

15. DISCONNECT INLET FUEL HOSE FROM FUEL FILTER
16. DISCONNECT FUEL RETURN HOSE FROM AIR PIPE

17. (w/PS) DISCONNECT PS PUMP
(a) Loosen the adjusting bolt, pivot bolt, and remove the drive belt.
(b) Remove the adjusting bolt, pivot bolt and PS pump.
(c) Suspend the PS pump.

18. (with A/C) DISCONNECT A/C COMPRESSOR
(a) Loosen the adjusting bolt and remove the drive belt.
(b) Remove the four compressor mounting bolts.
(c) Move the compressor aside and suspend it.

19. DISCONNECT SPEEDOMETER CABLE FROM TRANSAXLE

20. (M/T) REMOVE CLUTCH RELEASE CYLINDER WITHOUT DISCONNECTING PIPE AND HOSE.

21. (M/T) DISCONNECT CONTROL CABLES
(a) Remove the two clips, washers and retainers.
(b) Disconnect the control cables from the shift outer lever and select outer lever.

22. (A/T) DISCONNECT CONTROL CABLE
(a) Remove the clip and retainer.
(b) Disconnect the control cable from the shift lever.
23. RAISE VEHICLE

NOTICE: Be sure the vehicle is securely supported.

24. (4WD) DISCONNECT OIL COOLER HOSES

25. REMOVE FRONT EXHAUST PIPE
(a) Disconnect the oxygen sensor connector.
(b) Remove the two bolts and disconnect pipe from the catalytic converter.
(c) Remove the two nuts and exhaust pipe.
26. DISCONNECT DRIVE SHAFTS FROM TRANSAXLE
27. (4WD) DISCONNECT PROPELLER SHAFT

28. DISCONNECT FRONT, CENTER (2WD) AND REAR MOUNTINGS FROM CENTER MEMBER
(a) Remove the two hole covers.
(b) Remove the six bolts (2WD) or two bolts and two nuts (4WD) from each mounting.

(d) Remove the rear mounting bolt and mounting.

29. (4WD) REMOVE FRONT SUSPENSION CROSSMEMBER
Remove the eight bolts from the front suspension crossmember.

30. REMOVE ENGINE MOUNTING CENTER MEMBER
Remove the five bolts (2WD) or four bolts (4WD), insulators and member.

31. REMOVE ENGINE WITH TRANSAXLE FROM VEHICLE
(a) Attach the engine chain hoist to the lifting bracket on the engine.

HINT: Hang the engine wires and hoses on the chain
.

(b) Remove the three bolts and mounting stay.

(d) Remove the two bolts and mounting stay.
(e) Remove the three bolts and disconnect the LH mounting bracket from the transaxle bracket.

(f) Lift the engine out of the vehicle slowly and carefully. Clear the LH mounting while lowering the transaxle.

NOTICE: Be careful not to hit the power steering gear housing and throttle position sensor.

(g) Make sure the engine is clear of all wiring, hoses and cables.
(h) Place the engine with the transaxle onto the stand.
32. DISCONNECT FOLLOWING CONNECTORS:
(a) Back-up lamp switch connector (M/T)
(b) Neutral start switch connector (A/T)
33. REMOVE HOLE PLUG FROM REAR END PLATE
34. (A/T) REMOVE SIX TORQUE CONVERTER MOUNTING BOLTS
35. REMOVE STARTER
36. REMOVE TRANSAXLE FROM ENGINE

INSTALLATION OF ENGINE (4A-FE)

1. INSTALL TRANSAXLE TO ENGINE
2. INSTALL STARTER
3. (A/T) INSTALL SIX TORQUE CONVERTER MOUNTING BOLTS
4. INSTALL HOLE PLUG TO REAR END PLATE
5. CONNECT FOLLOWING CONNECTORS:
- Back-up lamp switch (M/T) Neutral start switch (A/T)

6. INSTALL ENGINE WITH TRANSAXLE TO VEHICLE
(a) Attach the engine hoist chain to the lifting bracket on the engine.

HINT: Hang the engine wires and hoses on the chain.

(b) Lower the engine into the engine compartment.
- Tilt the transaxle downward, lower the engine and clear the left mounting.

NOTICE: Be careful not to hit the power steering gear housing and throttle position sensor.
(c) Keep the engine level, and align each mounting with the bracket.

(d) Install the RH mounting insulator to the engine mounting bracket with the two nuts and bolt.
Torque:
Bolt 650 kg-cm (47 ft-lb, 64 N.m)
Nut 530 kg-cm (38 ft-lb, 52 N.m)
(e) Align the RH mounting insulator with the body bracket and temporarily install the mounting through bolt and nut.
Torque: 890 kg-cm (64 ft-lb, 87 N.m)

(f) Align the LH mounting insulator bracket with the transaxle case bracket. Temporarily install the three bracket bolts.
Torque: 490 kg-cm (35 ft-lb, 48 N.m)

(g) Install the RH mounting stay with the three bolts.
Torque: 430 kg-cm (31 ft-lb, 42 N.m)
(h) Install the LH mounting stay with the two bolts.
Torque: 210 kg-cm (15 ft-lb, 21 N.m)
(i) Remove the hoist chain from the engine.
7. RAISE VEHICLE

NOTICE: Be sure the vehicle is securely supported.

8. INSTALL ENGINE MOUNTING CENTER MEMBER
(a) Install and torque the rear mounting bolt.
Torque: 890 kg-cm (94 ft-lb, 87 N.m)

(b) Install and torque the front mounting bolt.

9. (4WD) INSTALL FRONT SUSPENSION CROSSMEMBER
Install the suspension crossmember with the eight bolts.
Torque:
(Front lower arm bolt) 2,100 kg-cm (152 ft-lb, 206 N.m)
(Rear bolt) 1,300 kg-cm (94 ft-lb, 127 N.m)

10. INSTALL FRONT, CENTER (2WD) AND REAR MOUNTINGS ONTO MEMBER
(a) Temporarily install the front and rear mountings and bolts.
(b) Align each bolt hole at the brackets with the member. Install and torque the bolts and nuts.
Torque: Front 490 kg-cm (35 ft-lb, 48 N.m)
Center (2WD) 530 kg-cm (38 ft-lb, 52 N.m)
Rear (2WD) 530 kg-cm (38 ft-lb, 52 N.m)
Rear (4WD) 580 kg-cm (42 ft-lb, 57 N.m)
(c) Install the two hole covers.
(d) Shake the engine several times to make sure that there is no load on the front and rear (All only) mounting insulators.

NOTICE:
On M/T, check that the insulator space is equal all the way around.
On A/T, check that the space above and below the insulator is equal.

HINT: On new insulators, the lower space is wider than the upper space On M/T, it does not matter if the insulator ribs (4 places) are broken.

11. (4WD) CONNECT PROPELLER SHAFT
12. CONNECT DRIVE SHAFTS TO TRANSAXLE

13. INSTALL FRONT EXHAUST PIPE
(a) Install both sets of new gaskets and the front pipe.
(b) Connect the exhaust pipe to the manifold. Install and torque two new nuts.
Torque: 630 kg-cm (46 ft-lb 62 N.m)
(c) Install the two bolts to the catalytic converter and bracket.
(d) Connect the oxygen sensor connector.
14. (4WD) CONNECT OIL COOLER HOSES
15. LOWER VEHICLE

16. CONNECT CONTROL CABLES
(a) Connect the control cables to the shift outer lever and select lever.
(b) Install the retainers, washers and clips.

17. (A/T) CONNECT CONTROL CABLE
(a) Connect the control cable to the shift lever.
(b) Install the retainer and clip.

18. (M/T) INSTALL CLUTCH RELEASE CYLINDER
(a) Install the release cylinder with the two bolts.
(b) Connect the bracket to the transaxle.
(c) Install the clip to the clutch pipe bracket.
19. CONNECT SPEEDOMETER CABLE TO TRANSAXLE

20. (with A/C) INSTALL A/C COMPRESSOR
Install the four compressor mounting bolts.
Torque: 250 kg-cm (18 ft-lb, 25 N.m)

21. (w/PS) INSTALL PS PUMP
(a) Connect the PS pump with pivot bolt and adjusting bolts.
(b) Install the drive belt. Torque the bolts.
Torque: 400 kg-cm (29 ft-lb, 39 N.m)
22. ADJUST DRIVE BELT

23. CONNECT FUEL RETURN HOSE TO AIR PIPE
24. CONNECT INLET HOSE TO FUEL FILTER Torque: 300 kg-cm (22 ft-lb, 29 N.m)

25. CONNECT HEATER WATER HOSES
(a) Connect the heater hose to the water inlet pipe.
(b) Connect the heater hose to the water inlet housing.
26. CONNECT ENGINE WIRE
(a) Push in the engine wire through the cowl panel.
(b) Connect the four connectors to the cowl wire and ECU.
(c) Install the center cover in front of the console box.
(d) Install rear and front console boxes.

(e) Connect the following connectors:
- Ground strap connector and bolt
- Check connector
- Vacuum sensor connector A/C wire connector
(f) Install the No.2 junction block and No.5 relay block with the three nuts.

27. CONNECT FOLLOWING HOSES:
(a) Connect the fuel return hose to the air pipe.
(b) (w/PS and/or with A/C), Connect the air hoses to the air pipe.
(c) Connect the following vacuum hoses to the intake chamber:
(1) Vacuum sensor hose to gas filter
(2) Brake booster vacuum hose
(3) (with A/C Two A/C vacuum hoses to actuator
28. INSTALL WASHER TANK

29. INSTALL AIR CLEANER ASSEMBLY
(a) Install the air cleaner support bracket with the two bolts.
(b) Install the air cleaner case with the three bolts.
(c) Connect the harness clamp to the boss of the case.
(d) Install the air cleaner filter element.
(e) Connect the air cleaner hose, and install the air cleaner cap with the four clips.
(f} Tighten the air cleaner hose clamp bolt.
(g) Connect the air hose to the air pipe.
(h) Connect the air intake temp. sensor connector to the air cleaner cap.
(i) Connect the vacuum hose to the charcoal canister.
30. (w/CRUISE CONTROL) INSTALL CRUISE CONTROL ACTUATOR
31. (A/T) CONNECT THROTTLE CABLE TO BRACKET
32. CONNECT ACCELERATOR WIRE TO BRACKET
33. INSTALL RADIATOR WITH COOLING FAN
34. (M/T) REFILL MANUAL TRANSAXLE AND TRANSFER WITH GEAR OIL
2WD C50/52 API GL-4 or GL-5 SAE 75W-90 2.7 qt. U.S.
4WD E55/57F5 API GL-5 SAE 75W-90, 80W-90 or 80W 5.3 U.S. qt.
35. (A/T) REFILL AUTOMATIC TRANSAXLE AND TRANSFER WITH FLUID
2WD/4WD DEXRON II 5.8 qt, Differential 1.5 qt.
36. REFILL WITH COOLANT
Close the radiator and engine drain cock and fill with coolant.
Total capacity (w/Heater):
M/T (Ex. AE92L - ACMXKK) liters (5.9 US qts, 4.9 Imp. qts)
M/T (AE92L - ACMXKK) 6.2 liters (6.2 US qts, 5.5 Imp. qts)
A/T 6.1 liters (6.4 US qts 5.4 Imp. qts)
37. REFILL WITH ENGINE OIL
Oil Grade: API grade SG
Capacity: Dry fill 3.7 liters (3.9 US qts, 3.3 Imp. qts)
Drain and refill (w/o Oil filter change) 3.0 liters (3.2 US qts, 2.6 Imp. qts)
Drain and refill (w/Oil filter change) 3.2 liters (3.4 US qts, 2.8 Imp. qts)
8. INSTALL BATTERY
39. START ENGINE AND CHECK FOR LEAKS
Warm up engine and inspect leakage.
40. RECHECK COOLANT AND ENGINE OIL LEVEL
41. INSTALL RH AND LH ENGINE UNDER COVERS
42. INSTALL HOOD