Engine: Service and Repair

REMOVAL
1. REMOVE BATTERY AND TRAY
2. REMOVE HOOD
3. REMOVE ENGINE UNDER COVERS
4. DRAIN ENGINE COOLANT
5. DRAIN ENGINE OIL
6. DRAIN TRANSAXLE OIL
7. DISCONNECT ACCELERATOR CABLE
8. REMOVE WASHER TANK





9. w/ Cruise Control System:
DISCONNECT CRUISE CONTROL ACTUATOR FROM BODY
a. Disconnect the actuator connector.
b. Disconnect the wire clamp from the actuator bracket.
c. Remove the 3 bolts, and disconnect the actuator from the body.





10. REMOVE AIR CLEANER CAP
a. Disconnect the MAP meter connector.
b. Disconnect the VSV connector for canister closed valve.
c. Disconnect the air hose from air cleaner cap.
d. Disconnect the 2 clamps, and disconnect the air cleaner cap from the air cleaner case.
e. Loosen the hose clamp, and disconnect the air cleaner hose from the throttle body.
f. Remove the air cleaner cap and air cleaner hose assembly.





11. REMOVE AIR CLEANER CASE
a. Remove the air filter.
b. Disconnect the engine wire from the clamp on the air cleaner case.
c. Remove the bolt holding VSV bracket to the air cleaner case.
d. Remove the 3 bolts and air cleaner case.





12. DISCONNECT TUBE, HOSES AND CONNECTORS
a. Remove the fuel tube clamp.
b. Disconnect the fuse tube from fuel pipe on vehicle side.
c. Disconnect the heater hose from water bypass pipe.
d. Disconnect the brake booster vacuum hose from pipe.
e. Disconnect the heater hose from water hose union on cylinder head.
f. Disconnect the DLC1.
13. REMOVE DRIVE BELT AND GENERATOR
14. REMOVE RADIATOR ASSEMBLY





15. w/A/C: DISCONNECT A/C COMPRESSOR FROM ENGINE
a. Disconnect the A/C compressor connector.
b. Using a torx socket (T40), remove the 3 bolts, and disconnect the A/C compressor from the engine.

HINT: Suspend the A/C compressor securely.





16. M/T: DISCONNECT CLUTCH RELEASE CYLINDER FROM TRANSAXLE
a. Remove the bolt, and disconnect the bracket from the transaxle.
b. Remove the clamp bolt, and disconnect the tube from the transaxle.
c. Remove the 2 bolts, and disconnect the release cylinder from the transaxle.





17. DISCONNECT TRANSAXLE CONTROL CABLE(S) FROM TRANSAXLE
18. DISCONNECT ENGINE WIRE FROM ENGINE COMPARTMENT RELAY BOX





a. Remove the 2 bolts and disconnect the relay box.
b. Disconnect the 3 connectors.
c. Disconnect the negative cable from the 2 clamps on the engine wire.
d. Disconnect the positive cable from the engine wire.





e. Remove the bolt, and disconnect the ground cable from the transaxle.
19. DISCONNECT ENGINE WIRE FROM CABIN





a. Remove the finish lower center panel.
b. Remove the 3 bolts and disconnect the ECM.
c. Disconnect the 3 (M/T and 3 A/T) or 4 (4 A/T) ECM connectors.
d. Disconnect the 5 cowl wire connectors from connectors on bracket.
e. Disconnect the heated oxygen sensor (Bank 1 sensor 2) connector.





f. Pull out the engine wire from the cabin.
20. DISCONNECT PS PUMP FROM ENGINE
a. Disconnect the PS oil pressure switch connector.





b. Using SST, remove the pulley bolt.
SST 09960-10010 (09962-01000, 09963-01000)
c. Remove the PS pump pulley.





d. Remove the 2 nuts and through bolts, and disconnect the PS pump from the engine.

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

21. REMOVE FRONT EXHAUST PIPE





a. Remove the bolt and pipe clamp, and disconnect the center exhaust pipe from the front exhaust pipe.





b. Remove the 2 bolts holding the front pipe to the exhaust manifold.
c. Remove the front exhaust pipe and 2 gaskets.
22. REMOVE DRIVE SHAFTS





23. REMOVE DRIVE SHAFT HEAT INSULATOR
Remove the 2 bolts, nut and heat insulator.





24. REMOVE FRONT ENGINE MOUNTING BRACKET
a. Remove the through bolt and nut holding the front mounting insulator to the mounting bracket.
b. Remove the 2 bolt and front engine mounting bracket.





25. REMOVE REAR MOUNTING BRACKET
a. Remove the through bolt holding the rear mounting insulator to the mounting bracket.
b. Remove the 3 (M/T and 4 A/T) or 2 (3 A/T) bolts and rear engine mounting bracket.
26. ATTACH ENGINE SLING DEVICE TO ENGINE HANGERS
Remove the 2 nuts, 2 clips and No. 2 cylinder head cover.
27. REMOVE ENGINE AND TRANSAXLE ASSEMBLY FROM VEHICLE





a. Install the 2 engine hangers in the correct direction.
Engine hanger part No.:
Front: 12281-20021
Rear: 12281-15040
Bolt part No.: 91512-B1016 2 pieces
Torque: 38 Nm (388 kgf-cm, 28 ft. lbs.)





b. Attach the engine sling device to the engine hangers.

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

c. M/T: Remove the 2 bolts and LH mounting stay.
d. Remove the through bolt and nut holding the LH mounting insulator to the mounting bracket.
e. Remove the 4 bolts and LH engine mounting insulator.





f. Disconnect the ground strap from the body.
g. Remove the bolt and 2 nuts, and disconnect the RH engine mounting bracket from the RH engine mounting insulator.





h. Remove the bolt holding the A/C piping clamp from the RH engine mounting insulator.
i. Remove the 3 bolts and RH engine mounting insulator.





j. Lift the engine out of the vehicle slowly and carefully.

HINT: Make sure the engine is clear of steering gear assembly all wiring, hoses and cables.

k. Place the engine and transaxle assembly on to the stand.
28. SEPARATE ENGINE AND TRANSAXLE

INSTALLATION
1. ASSEMBLE ENGINE AND TRANSAXLE
2. INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN VEHICLE
a. Attach the engine sling device to the engine hangers.





b. Lower the engine into the engine compartment. Tilt the transaxle downward, lower the engine and clear the LH mounting.

NOTICE: Be careful not to hit the steering gear assembly.

c. Keep the engine level, and align RH and LH mountings with the body bracket.





d. Install the RH engine mounting insulator with the 3 bolts.
Torque:
63.7 Nm (650 kgf-cm, 47 ft. lbs.) for bolt A
25.5 Nm (260 kgf-cm, 19 ft. lbs.) for bolt B
e. Install the bolt holding the A/C piping clamp to the RH engine mounting insulator.





f. Install the RH engine mounting bracket to the RH engine mounting insulator with the bolt and 2 nuts.
Torque:
63.7 Nm (650 kgf-cm, 47 ft. lbs.) for bolt
52.0 Nm (530 kgf-cm, 38 ft. lbs.) for nut
g. Connect the ground strap to the body.





h. Install the LH engine mounting insulator with the 4 bolts.
Torque: 65.0 Nm (660 kgf-cm, 48 ft. lbs.)
i. Install the through bolt and nut holding the LH mounting insulator to the mounting bracket.
Torque: 87 Nm (890 kgf-cm, 64 ft. lbs.)
j. M/T:
Install the LH mounting stay with the 2 bolts.
Torque: 20.6 Nm (210 kgf-cm, 15 ft. lbs.)





3. INSTALL REAR ENGINE MOUNTING BRACKET
a. Install the rear engine mounting bracket with the 3 (M/T, 4 A/T) or 2 (3 A/T) bolts.
Torque: 77.5 Nm (790 kgf-cm, 57 ft. lbs.)
b. Install the through bolt holding the rear mounting insulator to the mounting bracket.
Torque: 87.3 Nm (890 kgf-cm, 64 ft. lbs.)





4. INSTALL FRONT ENGINE MOUNTING BRACKET
a. Install the front mounting bracket holding the 2 bolts.
Torque: 77.5 Nm (790 kgf-cm, 57 ft. lbs.)
b. Install the through bolt and nut holding the front mounting insulator to the mounting bracket.
Torque: 87.3 Nm (890 kgf-cm, 64 ft. lbs.)
5. INSTALL DRIVE SHAFT HEAT INSULATOR
Install the heat insulator with the 2 bolts and nut.
Torque: 16.5 Nm (170 kgf-cm, 13 ft. lbs.)
6. INSTALL DRIVE SHAFTS
7. INSTALL FRONT EXHAUST PIPE





a. Place a new gasket to the exhaust manifold.
b. Install the 2 bolts and 2 springs holding the front exhaust pipe to the exhaust manifold.
Torque: 62 Nm (630 kgf-cm, 46 ft. lbs.)





c. Place a new gasket to the rear of the front exhaust pipe.
d. Attach the front exhaust pipe to the center exhaust pipe.
e. Install a new pipe clamp with the bolt.
Torque: 32 Nm (330 kgf-cm, 24 ft. lbs.)
f. Install a new gasket and the heated oxygen sensor with 2 new nuts.
Torque: 20 Nm (200 kgf-cm, 14 ft. lbs.)





8. INSTALL PS PUMP
a. Install the PS pump with the 2 through bolts and nuts.
Torque: 37 Nm (370 kgf-cm, 27 ft. lbs.)
b. Install the PS pump pulley with the pulley nut.
c. Using SST, torque the pulley nut.
SST 09960-10010 (09962-01000, 09963-01000)
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)
d. Connect the PS oil pressure switch connector.
9. CONNECT ENGINE WIRE TO CABLE
a. Push in the engine wire to the cabin
b. Connect the 3 (M/T and 3 A/T) or 4 (4 A/T) ECM connectors.
c. Connect the 5 cowl wire connectors to connectors on bracket.
d. Connect the heated oxygen sensor (bank 1 sensor 2) connector.
e. Install the ECM with the 3 bolts.
f. Install the finish lower center panel.
10. CONNECT ENGINE WIRE TO ENGINE COMPARTMENT RELAY BOX
a. Connect the ground cable to the transaxle.
b. Connect the positive cable to the engine wire.
c. Connect the negative cable to the 2 clamps on the engine wire.
d. Connect the 3 connectors.
e. Install the relay box with the 2 bolts.
11. CONNECT TRANSAXLE CONTROL CABLE(S) TO TRANSAXLE
12. M/T: CONNECT CLUTCH RELEASE CYLINDER TO TRANSAXLE
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)





13. w/A/C: INSTALL A/C COMPRESSOR
a. Using a torx socket (T40), install the A/C compressor with the 3 bolts.
Torque: 24.5 Nm (245 kgf-cm, 18 ft. lbs.)
b. Connect the A/C compressor connector.
14. INSTALL RADIATOR ASSEMBLY
15. INSTALL GENERATOR AND DRIVE BELT





16. CONNECT CONNECTORS, HOSES AND TUBE
a. Connect the DLC1.
b. Connect the heater hose to water hose union on cylinder head.
c. Connect the brake booster vacuum hose to pipe.
d. Connect the heater hose to water bypass pipe.
e. Connect the fuel tube to fuel pipe on vehicle side.
f. Install the fuel tube clamp.





17. INSTALL AIR CLEANER CASE
a. Install the air cleaner case with the 3 bolts.
b. Install the bolt holding VSV bracket to the air cleaner case.
c. Connect the engine wire to the clamp on the air cleaner case.
d. Install the air filter.





18. INSTALL AIR CLEANER CAP
a. Connect the air cleaner hose to the throttle body.
b. Attach the air cleaner cap to the air cleaner case, and install the 2 clamps.
c. Tighten the air cleaner hose clamp.
d. Connect the air hose for air cleaner cap.
e. Connect the MAF meter connector.
f. Connect the VSV connector for canister closed valve.





19. w/ Cruise Control System:
INSTALL CRUISE CONTROL ACTUATOR
a. Install the actuator with the 3 bolts.
b. Connect the wire clamp to the actuator bracket.
c. Connect the actuator connector.
20. INSTALL WASHER TANK
21. CONNECT ACCELERATOR CABLE
22. INSTALL ENGINE UNDER COVERS
23. INSTALL HOOD
24. FILL ENGINE WITH OIL
25. FILL WITH ENGINE COOLANT
26. START ENGINE AND CHECK FOR LEAKS
27. RECHECK ENGINE COOLANT AND OIL LEVELS