Engine: Service and Repair

1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures.
2. Remove hood, then disconnect battery.
3. Remove battery, base, bracket and engine ground cable.
4. Remove throttle cable and cruise control cable by loosening locknuts, then slip cable end out of throttle linkage. Do not loosen adjusting nut.
5. Remove lower radiator hose, then air intake duct.
6. Remove battery cable from fuse/relay box and ABS fuse/relay box, then disconnect engine wire harness connectors on right side of engine compartment. Tag all electrical connections and vacuum hoses for installation reference.
7. Remove brake booster vacuum hose, then EVAP control canister hose.
8. Relieve fuel pressure as described under Technician Safety Information.
9. Remove vacuum hoses, then power steering hose clamp.
10. Disconnect engine wire harness connectors, terminal and clamps on left side of engine compartment, then disconnect injector resistor electrical connector.
11. Remove power steering pump mounting nuts adjusting bolt, belt and pump. Do not disconnect power steering hoses.
12. Remove alternator mounting bolt, mounting nut, adjusting bolt, electrical connector and alternator terminal, then remove alternator belt and alternator.
13. Remove alternator bracket, then radiator cap. Use care when removing radiator cap to avoid scalding by hot coolant or steam.
14. Raise and support vehicle.
15. Remove front tires/wheels and splash shield, then drain engine coolant, transmission fluid and engine oil.
16. Lower vehicle, then remove radiator hoses and heater hoses.
17. Remove automatic ATF cooler hoses, then radiator assembly.
18. Remove A/C compressor. Do not disconnect A/C hoses.
19. Raise and support vehicle, then disconnect heated oxygen sensor electrical connector and remove exhaust pipe A.
20. Scribe a mark on center and rear beam, then remove mounting bolts.
21. Remove shift cable, then damper fork.
22. Remove suspension lower arm ball joints as outlined in Front Suspension & Steering.
23. Remove driveshafts. Do not pull on driveshaft, as constant velocity (CV) joint may come apart. Pull straight out to avoid damaging differential oil seal or intermediate shaft dust seal.
24. Remove front mount bracket, then separate stabilizer from lower arm.
25. Remove lower arms from rear beam, then front beam.
26. Lower vehicle and attach chain hoist to engine.
27. Separate rear mount and bracket then side mounts.
28. Remove transmission mount and bracket, then remove engine.

Fig. 7 Engine Mount Tightening Sequence:

29. Reverse procedure to install, noting the following:
a. Position side engine mount by putting a 6 x 0.00 mm bolt through mount and bracket. Tighten mount bolt to specification, then remove 6 x 100 mm bolt. Do not tighten bolts on engine side. Repeat procedure for transmission mount.
b. Install rear mount bracket, then install front beam. Do not tighten bolts and nuts.
c. Align mark, then install center beam mounting bolts and tighten to specification.
d. Install front beam mounting bolts, then install lower arms and stabilizer. Tighten to specification
e. Install front mount bracket, then tighten to specification. Do not tighten bolts on engine side.
f. Tighten bolts/nuts on side engine mount, transmission mount, and front mount bracket to specification, Fig. 7.
g. When installing driveshafts use new spring clips and ensure driveshafts click into groove in differential.
h. Bleed cooling system.
i. Adjust all control cables and belts as required.
30. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures.