Engine: Service and Repair

REMOVAL
1. REMOVE CENTER ENGINE UNDER COVER
2. REMOVE FRONT WHEELS
3. REMOVE LH AND RH FENDER LINERS
4. REMOVE LH AND RH FRONT FENDER APRON SEALS
5. DRAIN ENGINE COOLANT

CAUTION: Do not remove the radiator cap while the engine and radiator are still hot.

6. A/T: DRAIN ATF
7. M/T: DRAIN TRANSMISSION OIL
8. DRAIN PS FLUID
9. REMOVE BATTERY AND TRAY
10. REMOVE AIR CLEANER CAP AND CASE
a. Disconnect the IAT sensor connector.
b. Disconnect the MAF sensor connector.
c. Disconnect the VSV connector for the EVAP.
d. Disconnect the PCV hose.
e. Disconnect the 2 EVAP hoses.
f. Remove the air cleaner cap with the intake air hose.
g. Remove the air filter.
h. Remove the 3 bolts and air cleaner case.
11. DISCONNECT RADIATOR HOSES
12. A/T: DISCONNECT OIL COOLER HOSE
Disconnect the 2 oil cooler hoses.
13. DISCONNECT HEATER HOSES
14. DISCONNECT TRANSAXLE CONTROL CABLE(S)
15. M/T: DISCONNECT CLUTCH RELEASE CYLINDER AND TUBE
16. DISCONNECT CONNECTORS, WIRES, CABLES AND CLAMPS
a. Disconnect the ground wires.
1) RH side: Remove the bolt and disconnect the ground strap.
2) LH side: Disconnect the 2 ground strap connectors.
3) Remove the bolt and disconnect the negative battery cable.
b. Remove the nut and disconnect the starter cable.
c. Disconnect the starter connector.
d. Disconnect the engine wire clamps from the RH fender apron.
17. DISCONNECT ENGINE WIRE FROM CABIN
a. Remove the No. 2 instrument panel.
b. Disconnect the 3 ECM connectors and 4 cowl wire connectors.
c. Disconnect the DLC1 from the bracket.
d. Disconnect the grommet from the cowl panel, and pull out the engine wire.
18. DISCONNECT HOSES
a. Disconnect the brake booster vacuum hose.
b. Disconnect the fuel inlet hose.





c. Disconnect the PS hose from the reservoir tank.





d. Disconnect the PS hose from the PS return tube.
19. REMOVE GENERATOR





20. DISCONNECT A/C COMPRESSOR w/ PIPES
a. Disconnect the A/C compressor connector.
b. Remove the 4 bolts, and disconnect the A/C compressor from the engine.
c. Suspend the A/C compressor securely.





21. REMOVE ENGINE MOVING CONTROL ROD
Remove the 3 bolts and control rod.
22. DISCONNECT INTERMEDIATE SHAFT (for steering gear box)
23. DISCONNECT LH AND RH STABILIZER BAR LINKS
Remove the nut and disconnect the stabilizer bar link.
24. REMOVE DRIVE SHAFTS
25. REMOVE FRONT EXHAUST PIPE
At this time, disconnect the heated oxygen sensor connector from the front suspension member.





26. A/T:
REMOVE DRIVE PLATE BOLTS
a. Remove the cover.
b. Hold the crankshaft pulley bolt and loosen one of the drive plate bolts.
c. Turn the crankshaft pulley clockwise and loosen the other 5 drive plate bolts





27. REMOVE ENGINE AND TRANSAXLE w/ SUSPENSION MEMBER ASSEMBLY
a. Attach an engine jack to the front suspension member.
b. Remove the 2 bolts, 4 nuts, 4 long bolts and 4 suspension member lower braces.
c. Lower the engine and transaxle with the suspension member.

NOTICE: Be careful not to damage the engine wire, cables, hoses and pipes.

28. REMOVE NO. 2 CYLINDER HEAD COVER
Remove the 2 nuts, 2 grommets and No. 2 cylinder head cover.
29. DISCONNECT PS PUMP
a. Disconnect the PS connector.
b. Remove the 2 bolts and disconnect the PS pump from the engine.





30. SEPARATE ENGINE AND SUSPENSION MEMBER
a. Using a hoist or a similar object, hook the engine hangers.

NOTICE: When reusing the engine hangers, replace the engine hangers bolts.

Torque: 38 Nm (390 kgf-cm, 28 ft. lbs.)
b. Remove the 3 member bolts.
c. Separate the engine and T/A by a hoist or a similar object.
31. DISCONNECT ENGINE WIRE FROM T/A
a. A/T: Disconnect the 2 A/T connectors.
b. A/T: Disconnect the neutral start switch connector.
c. Disconnect the speed sensor connector.
d. Disconnect the back up lamp switch connector.
e. Disconnect the wire clamps.
f. Disconnect the engine wire from the T/A.
32. REMOVE STARTER
Remove the 2 bolts and starter.
33. SEPARATE ENGINE AND T/A
a. M/T: Remove the 10 bolts and separate the engine and T/A.
b. A/T: Remove the 9 bolts and separate the engine and T/A.
34. M/T: REMOVE CLUTCH DISC AND COVER
a. Loosen the 6 bolts diagonally and equally.
b. Remove the 6 bolts, clutch cover and disc.
35. M/T: REMOVE FLYWHEEL
a. Loosen the 8 bolts diagonally and equally.
b. Remove the 8 bolts and flywheel.
36. A/T: REMOVE DRIVE PLATE
Remove the 8 bolts, 2 spacers and drive plate.
37. REMOVE DRIVE SHAFT SUPPORT BRACKET
Remove the 3 bolts and drive shaft support bracket.
38. REMOVE LH ENGINE SUPPORT BRACKET
Remove the 3 bolts and LH engine support bracket.

INSTALLATION





1. M/T: INSTALL FLYWHEEL
a. Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive: Part No. 08833-00070 or equivalent
b. Install and uniformly tighten the 8 bolts, in several passes, in the sequence shown in the illustration.
Torque: 130 Nm (1,330 kgf-cm, 96 ft. lbs.)
2. M/T: INSTALL CLUTCH DISC AND COVER





3. A/T: INSTALL DRIVE PLATE
a. Install the front spacer, drive plate and rear spacer.
b. Apply adhesive to 2 or 3 threads of the mounting bolt end.
Adhesive: Part No. 08833-00070 or equivalent
c. Install and uniformly tighten the 8 mounting bolts, in several passes, in the sequence shown in the illustration.
Torque: 98 Nm (1,000 kgf-cm, 72 ft. lbs.)





4. M/T:
INSTALL T/A TO ENGINE
Install the T/A to the engine with the 10 bolts.
Torque:
64 Nm (650 kgf-cm, 47 ft. lbs.) for bolt A
46 Nm (470 kgf-cm, 34 ft. lbs.) for bolt B
44 Nm (450 kgf-cm, 32 ft. lbs.) for bolt C
5. A/T:
INSTALL T/A TO ENGINE





a. Install the 5 T/A upper side bolts.
Torque:
64 Nm (650 kgf-cm, 47 ft. lbs.) for bolt A
46 Nm (470 kgf-cm, 34 ft. lbs.) for bolt B





b. Install the 4 T/A lower side bolts.
Torque: 44 Nm (450 kgf-cm, 32 ft. lbs.)





6. A/T:
INSTALL DRIVE PLATE BOLTS
a. Hold the crankshaft pulley bolt and install the green colored bolt.
b. Turn and hold the crankshaft pulley bolt, and install the other 5 bolts.
c. Tighten the bolts diagonally and equally.
Torque: 41 Nm (420 kgf-cm, 30 ft. lbs.)
7. INSTALL STARTER
Install the starter with the 2 bolts.
Torque: 37 Nm (380 kgf-cm, 28 ft. lbs.)
8. INSTALL LH ENGINE MOUNTING BRACKET
Install the bracket with the 3 bolts.
9. INSTALL DRIVE SHAFT SUPPORT BRACKET
Install the bracket with the 3 bolts.
Torque: 34 Nm (350 kgf-cm, 25 ft. lbs.)





10. INSTALL ENGINE AND TRANSAXLE TO FRONT SUSPENSION MEMBER
a. Using a hoist or similar object, place the engine on the suspension member.
b. Mount the engine with the bolts.
Torque:
95 Nm (970 kgf-cm, 70 ft. lbs.) for bolt A
89 Nm (910 kgf-cm, 66 ft. lbs.) for bolt B
143 Nm (1,460 kgf-cm, 106 ft. lbs.) for bolt C (M/T)
95 Nm (970 kgf-cm, 70 ft. lbs.) for bolt C (A/T)
89 Nm (910 kgf-cm, 66 ft. lbs.) for drive shaft support bracket (M/T)





11. INSTALL PS PUMP
a. Install the PS pump with the 2 bolts.
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)
b. Connect the PS connector.
12. INSTALL ENGINE AND TRANSAXLE w/ FRONT SUSPENSION MEMBER ASSEMBLY
a. Using an engine jack, support the engine and transaxle with suspension member assembly.
b. Attach the engine and transaxle with suspension member assembly to the vehicle.
c. Install the 2 bolts, 4 nuts, 4 long bolts, front LH and RH lower braces and rear LH and RH lower braces.
Torque:
181 Nm (1,850 kgf-cm, 134 ft. lbs.) for bolt A
32 Nm (330 kgf-cm, 24 ft. lbs.) for bolt B
36 Nm (370 kgf-cm, 27 ft. lbs.) for nut C
d. Remove the engine jack.
13. INSTALL FRONT EXHAUST PIPE
14. CONNECT LH AND RH DRIVE SHAFTS
Connect the drive shaft to the steering knuckle.
15. CONNECT LH AND RH STABILIZER BAR LINKS
Connect the stabilizer link with the nut.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)

HINT: If the ball joint turns together with the nut, use a 5 mm hexagon wrench to hold the stud.

16. CONNECT INTERMEDIATE SHAFT (for steering gear box)





17. CONNECT PS HOSE TO PS RETURN TUBE





18. CONNECT PS HOSE TO RESERVOIR





19. INSTALL ENGINE MOVING CONTROL ROD
Install the control rod and 3 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
20. CONNECT A/C COMPRESSOR
Connect the A/C compressor with the 4 bolts.
Torque: 25.5 Nm (260 kgf-cm, 19 ft. lbs.)
21. INSTALL GENERATOR AND DRIVE BELT
22. CONNECT HOSES
a. Connect the brake booster vacuum hose to the intake manifold.
b. Connect the fuel inlet hose to the fuel filter.
c. Connect the MAP sensor vacuum hose to the gas filter on the intake manifold.
23. CONNECT CONNECTORS, WIRES, CABLES AND CLAMPS
a. Connect the ground cable.
1) Connect the ground cable to the transaxle.
2) LH side: Connect the 2 ground strap connectors.
3) RH side: Connect the 2 ground strap connectors.
b. Connect the engine wire to the clamp on the fuel filter.
c. Connect the engine wire protector clamp to the battery bracket.
d. Connect the wire clamp to the bracket for the MAP sensor.
e. Connect the MAP sensor connector.
f. Connect the engine wire clamp to the bracket on the RH fender apron.
g. Connect the starter connector.
h. Connect the starter wire.
i. Connect the wire clamp to the generator.
j. Connect the generator connector.
k. Connect the generator wire.





24. CONNECT ENGINE WIRE TO CABIN
Connect the engine wire to the cabin.
1) Install the engine wire and connect the grommet to the cowl panel.
2) Connect the DLC1 to the bracket.
3) Connect the 3 ECM connectors and 4 cowl wire connectors.
4) Install the No. 2 instrument panel.
25. M/T:
CONNECT CLUTCH RELEASE CYLINDER AND TUBE FROM TRANSAXLE
26. CONNECT TRANSAXLE CONTROL CABLE(S)
27. A/T:
ADJUST SHIFT LEVER POSITION
28. CONNECT HEATER HOSES
29. A/T:
CONNECT OIL COOLER HOSES
30. CONNECT RADIATOR HOSE
31. INSTALL AIR CLEANER CAP AND CASE
a. Install the air cleaner case and 3 bolts.
b. Install the air filter.
c. Install the air cleaner cap and hose assembly.
d. Connect the hose clamp and air cleaner hose to the throttle body.
e. Connect the 2 clamps and air cleaner cap to the air cleaner case.
f. Connect the IAT sensor connector.
g. Connect the VSV connector for the EVAP
h. Connect the PCV hose to the cylinder head cover.
i. Connect the EVAP hose to the throttle body.
j. Connect the EVAP hose to the VSV.
32. INSTALL BATTERY AND TRAY
33. FILL ENGINE COOLANT AND BLEED AIR
34. FILL PS FLUID AND BLEED AIR
35. A/T: FILL ATF
36. M/T: FILL TRANSMISSION OIL
37. INSTALL LH AND RH FRONT FENDER APRON SEALS
38. INSTALL LH AND RH FENDER LINERS
39. INSTALL CENTER ENGINE UNDER COVER
40. ADJUST FRONT WHEEL ALIGNMENT