Engine: Service and Repair

Engine Assembly





Removal
1. Disconnect battery ground and positive cable.
2. Remove battery.
3. Make alignment mark on the engine hood and hinges before removal in order to return the hood to original position exactly.
4. Remove engine hood.
5. Drain radiator coolant.
6. Disconnect ion sensing module harness connectors, and manifold absolute pressure sensor harness connectors from sensor on common chamber.
7. Disconnect throttle position sensor harness connectors from throttle body.
8. Disconnect air duct with air cleaner cover.
9. Remove air cleaner assembly.
10. Disconnect canister vacuum hose.
11. Disconnect vacuum booster hose.
12. Disconnect three engine harness connectors.
13. Disconnect harness connector to transmission (left front side of engine compartment), disconnect shift on the fly harness connector from front side of front axle and remove transmission harness bracket from engine left side.
14. Disconnect ground cable between engine and frame.
15. Disconnect bonding cable connector on the back of right dash panel.
16. Disconnect bonding cable terminal on the left bank.
17. Disconnect starter harness connector from starter.
18. Disconnect generator harness connector from generator.
19. Disconnect coolant reserve tank hose from radiator.
20. Remove radiator upper and lower hoses.
21. Remove upper fan shroud.
22. Remove cooling fan assembly four fixing nuts, then the cooling fan assembly.
23. Move drive belt tensioner, to loose side using wrench, then remove drive belt.
24. Remove power steering pump fixing bolts, then power steering pump. Place the power steering pump along with piping on the body side.
25. Remove air conditioning compressor fixing bolts from bracket and place the compressor along with piping on the body side.
26. Remove four 02 sensor harness connectors (two each bank) from exhaust front pipe.
27. Remove three exhaust pipe fixing nuts from each bank.
28. Remove two exhaust pipe fixing nuts from each exhaust pipe, then move exhaust pipe to rear side of vehicle.
29. Remove flywheel dust covers.
30. Disconnect two heater hoses from engine.
31. Disconnect fuel hose from right side of transmission.

Caution: Plug fuel pipe on engine side and fuel hose from fuel tank.

32. Remove transmission assembly.
33. Support the engine by engine hoist.
34. Remove two left side engine mount fixing bolts from engine mount on chassis side.
35. Remove two right side engine mount fixing bolts from engine mount on chassis side.
36. Remove engine assembly.

Installation

CAUTION: When assembling the engine and transmission, confirm that dowels have been mounted in the specified positions at the engine side.





NOTE: Take care that dowel positions are different between the manual transmission and the automatic transmission.
If the engine is assembled in the condition that the dowels have not been mounted in the specified positions, the transmission may be damaged.

1. Install engine assembly. Tighten engine mount fixing bolts to frame to the specified torque.
Torque: 41 Nm (30 ft. lbs.)
2. Reconnect fuel hose to fuel pipe on engine.
3. Install transmission assembly.
4. Reconnect two heater hoses to engine.
5. Install flywheel dust covers.








6. Install exhaust pipe and temporarily tighten two (each bank) rear exhaust flange nuts then tighten three stud nuts (each bank) between exhaust manifold and exhaust pipe, finally tighten rear side nuts to the specified torque.
Torque:
Nuts: 43 Nm (32 ft. lbs.)
Stud nuts: 67 Nm (49 ft. lbs.)
7. Reconnect 02 sensor connector.
8. Install cooling fan assembly and tighten bolts/nuts to the specified torque.
Torque: 22 Nm (16 ft. lbs.) for fan pulley and fan bracket.
Torque: 7.5 Nm (66.4 inch lbs.) for fan and clutch assembly.
9. Install air conditioner compressor to engine and tighten to the specified torque.
6VE1
Torque:
M8 bolts: 22 Nm (16 ft. lbs.)
M10 Bolts: 43 Nm (32 ft. lbs.)
10. Install power steering pump, tighten fixing bolt to the specified torque.
Torque:
M8 bolts: 22 Nm (16 ft. lbs.)
M10 bolts: 46 Nm (34 ft. lbs.)





11. Move drive belt tensioner to loose side using wrench, then install drive belt to normal position.
12. Install upper fan shroud.
13. Reconnect radiator upper and lower hoses.
14. Reconnect coolant reserve tank hose to radiator.
15. Reconnect generator harness connector.
16. Reconnect starter harness connector.
17. Reconnect bonding cable terminal on left bank
18. Reconnect bonding cable terminal on the back of right dash panel.
19. Reconnect ground cable between engine and chassis.
20. Reconnect harness connector to transmission and install transmission harness bracket on engine left side.
21. Reconnect three engine harness connectors.
22. Reconnect vacuum booster hose.
23. Reconnect canister vacuum hose.
24. Install air cleaner assembly.
25. Reconnect air duct.





26. Reconnect throttle position sensor harness connector.
27. Reconnect manifold absolute pressure sensor harness connectors.





28. Reconnect Ion sensing module connectors as shown in illustration.
29. Install engine hood to the original position.