Engine: Service and Repair
REMOVAL
1. DISCONNECT BATTERY NEGATIVE (-) TERMINAL AND HV BATTERY SERVICE PLUG
2. REMOVE OUTER FRONT COWL TOP PANEL ASSEMBLY
3. DRAIN HV COOLANT
4. DRAIN ENGINE COOLANT
5. REMOVE CONVERTER AND INVERTER ASSEMBLY
6. REMOVE HEATER UNIT WATER PUMP
7. REMOVE AIR CLEANER ASSEMBLY
a. Disconnect the MAF meter connector.
b. Disconnect the EVAP hose from the air cleaner case.
c. Loosen the 2 hose clamps.
d. Remove the 2 bolts and air cleaner assembly.
8. DISCONNECT CONNECTORS, CLAMPS AND HOSES
a. Disconnect the engine wire clamps.
b. Disconnect the heated oxygen sensor connector.
c. Disconnect the 2 power steering connectors.
d. Disconnect the VSV connector for purge line.
e. Disconnect the VSV hose for purge line.
f. Disconnect the ground strap from RH fender apron.
g. Disconnect the ground strap from LH fender apron.
9. REMOVE AIR INLET
10. REMOVE ENGINE COOLANT RESERVOIR TANK
11. DISCONNECT RADIATOR HOSES FROM RADIATOR
12. DISCONNECT HEATER HOSE FROM CYLINDER BLOCK
13. DISCONNECT SHIFT LEVER CABLE
14. REMOVE BRAKE RESERVOIR TANK
a. Disconnect the brake fluid level sensor connector.
b. Remove the 2 bolts and remove the reservoir tank and suspend it.
15. DISCONNECT ENGINE WIRE FROM CABIN
a. Remove the ECM.
b. Disconnect the grommet from the cowl panel, and pull out the engine wire.
16. REMOVE J/B NO. 1 FROM RH FENDER APRON
17. DISCONNECT FUEL TUBE
Disconnect the fuel tube from the fuel pump.
18. REMOVE DRIVE BELT
19. REMOVE ENGINE UNDER COVERS
20. REMOVE A/C COMPRESSOR
a. Disconnect the A/C compressor connector.
b. Remove the 4 bolts and disconnect the A/C compressor from the engine.
HINT: Suspend the A/C compressor securely.
21. DISCONNECT INTERMEDIATE EXTENSION FROM STEERING ASSEMBLY
22. REMOVE EXHAUST PIPE
a. Disconnect the heated oxygen sensor from the exhaust pipe.
b. Remove the 2 springs and 3 bolts.
c. Disconnect the 2 O-rings, and remove the exhaust pipe and 2 gaskets.
23. DISCONNECT TIE ROD END FROM STEERING KNUCKLE
24. DISCONNECT STABILIZER BAR LINK
Remove the nut and disconnect the stabilizer bar link from the suspension member.
25. DISCONNECT BALL JOINT FROM LOWER ARM
Remove the 2 bolts and 4 nuts, disconnect the ball joint.
26. REMOVE DRIVE SHAFTS
27. REMOVE TORQUE ROD
Remove the 4 bolts and 2 nuts and torque rod from the body.
28. REMOVE SUSPENSION MEMBER
Remove the 4 bolts and disconnect the suspension member from the body.
29. SET ENGINE JACK
NOTICE: Using chain, hold the engine tightly.
30. DISCONNECT ENGINE MOUNTINGS
a. Remove the 2 bolts, 2 nuts and disconnect the RH engine mounting insulator from the bracket.
b. Remove the nut and disconnect the LH engine mounting from the insulator.
31. REMOVE ENGINE AND TRANSAXLE ASSEMBLY
a. Lower the engine out of vehicle slowly and carefully.
NOTICE: Make sure the engine is clear of all wiring, hoses and cables.
b. Using a engine sliding device, and place the engine and transaxle assembly onto the stand.
32. SEPARATE ENGINE AND TRANSAXLE
a. Remove the 2 bolts and dust cover.
b. Remove the 6 bolts and transaxle from the engine.
33. REMOVE DAMPER DISC
Using SST, hold the crankshaft pulley, remove the 6 bolts and damper disc and spring.
SST 09213-58012 (91111-580845), 09330-00021
34. REMOVE FLYWHEEL
Using SST, hold the crankshaft pulley, remove the 6 bolts and flywheel.
SST 09213-58012 (91111-580845), 09330-00021
INSPECTION
1. INSPECT DAMPER DISC FOR WEAR OR DAMAGE
Using vernier calipers, measure the damper disc thickness.
Standard thickness: 6.2 - 6.6 mm (0.244 - 0.260 inch)
Minimum thickness: 4.9 mm (0.193 inch)
If the thickness is less than the minimum, replace the damper disc.
2. INSPECT FLYWHEEL RUNOUT
Using a dial indicator, check the flywheel runout.
Maximum runout: 0.1 mm (0.004 inch) If necessary, replace the flywheel.
INSTALLATION
1. INSTALL FLYWHEEL
a. Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
b. Install and uniformly tighten the new 6 bolts in several passes, in the sequence shown.
Torque: 84 Nm (857 kgf-cm, 62 ft. lbs.)
c. Retighten the flywheel bolts by 90° in the numerical order shown.
2. INSTALL DAMPER DISC
a. Insert SST in the damper disc, then insert them in the flywheel.
SST 09301-00110
HINT: Take care not to insert damper disc in the wrong direction.
b. Set the damper spring on the damper disc.
c. Following the procedures shown in the illustration, tighten the 6 bolts in the order starting the bolt locating near the knock pin on the top.
Torque: 16 Nm (163 kgf-cm, 12 ft. lbs.)
HINT:
- Following the order in the illustration, tighten the bolts at a time evenly.
- Move SST up and down, right and left lightly, after checking that the disc in the center, tighten the bolts.
3. INSTALL TRANSAXLE TO ENGINE
a. Attach the transaxle to the engine, and install the 6 bolts.
Torque: 33 Nm (337 kgf-cm, 24 ft. lbs.)
b. Install the dust cover.
c. Install the LH engine mounting bracket.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)
4. SET ENGINE JACK
NOTICE: Using a chain, hold the engine tightly.
5. INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN VEHICLE
a. Raise the engine into the engine compartment.
b. Keep the engine level, and align RH and LH mountings with the insulator.
c. Connect the LH mounting bracket to the insulator with the nut.
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)
d. Connect the RH mounting bracket to the insulator with the 2 bolts and 2 nuts.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)
6. INSTALL SUSPENSION MEMBER
Connect the suspension member with the 4 bolts.
Torque:
Bolt A: 113 Nm (1,152 kgf-cm, 83 ft. lbs.)
Bolt B: 157 Nm (1,601 kgf-cm, 116 ft. lbs.)
7. INSTALL TORQUE ROD
a. Install the torque rod through bolt and nut.
Torque: 100 Nm (1,020 kgf-cm, 74 ft. lbs.)
b. Install the 2 bolts.
Torque: 60 Nm (612 kgf-cm, 44 ft. lbs.)
8. INSTALL DRIVE SHAFTS
9. CONNECT BALL JOINT TO LOWER ARM
Torque: 142 Nm (1,448 kgf-cm, 105 ft. lbs.)
10. CONNECT STABILIZER BAR LINK
Torque: 74 Nm (755 kgf-cm, 55 ft. lbs.)
11. CONNECT TIE ROD END TO STEERING KNUCKLE
12. INSTALL EXHAUST PIPE
a. Install the 2 gaskets to the exhaust pipe and connect the 2 O-rings.
b. Install the 2 springs and 3 bolts.
Torque:
Front exhaust pipe: 62 Nm (630 kgf-cm, 46 ft. lbs.)
Tailpipe: 32 Nm (326 kgf-cm, 24 ft. lbs.)
c. Connect the hose to the actuator.
d. Connect the heated oxygen sensor.
13. INSTALL A/C COMPRESSOR
a. Connect the A/C compressor to the engine with the 4 bolts.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
b. Connect the A/C compressor connector.
14. CONNECT INTERMEDIATE EXTENSION STEERING ASSEMBLY
15. INSTALL DRIVE BELT)
16. CONNECT FUEL TUBE
17. INSTALL J/B NO. 1 TO RH FENDER APRON
18. CONNECT ENGINE WIRE TO CABIN
a. Pull in the engine wire to the cowl panel and connect the grommet.
b. Connect the ECM connectors.
c. Install the ECM.
19. INSTALL BRAKE RESERVOIR TANK
a. Install the reservoir tank with the 2 bolts.
b. Connect the brake fluid level sensor connector.
20. CONNECT SHIFT LEVER CABLE TO TRANSAXLE
21. CONNECT HEATER HOSE TO CYLINDER BLOCK
22. CONNECT 2 RADIATOR HOSES TO RADIATOR
23. INSTALL ENGINE COOLANT RESERVOIR TANK
24. INSTALL AIR INLET
25. CONNECT CONNECTORS, CLAMPS AND HOSES
a. Connect the Ground strap from LH fender apron.
b. Connect the Ground strap from RH fender apron.
c. Connect the VSV hose for purge line.
d. Connect the VSV connector for purge line.
e. Connect the 2 power steering connectors.
f. Connect the Heated oxygen sensor connector.
g. Connect the Engine wire clamps.
26. INSTALL AIR CLEANER ASSEMBLY
a. Install the air cleaner assembly with the 2 bolts.
b. Tighten the 2 hose clamps.
c. Connect the EVAP hose to the air cleaner case.
d. Connect the MAF meter connector.
27. INSTALL HEATER UNIT WATER PUMP
28. INSTALL CONVERTER AND INVERTER ASSEMBLY
29. INSTALL OUTER FR COWL TOP PANEL ASSEMBLY
30. FILL WITH ENGINE COOLANT
31. FILL WITH HV COOLANT
32. INSTALL ENGINE UNDER COVERS
33. CONNECT BATTERY NEGATIVE (-) TERMINAL AND HV BATTERY SERVICE PLUG
34. ROAD TEST VEHICLE
Check for abnormal noise, shock slippage, correct shift points and smooth operation.
35. RECHECK ENGINE COOLANT AND HV TRANSAXLE COOLANT