Engine: Service and Repair
REMOVAL
1. REMOVE TRANSMISSION
2. REMOVE ENGINE UNDER COVER
3. DRAIN ENGINE COOLANT AND OIL
4. REMOVE HOOD
5. REMOVE RADIATOR ASSEMBLY
6. REMOVE FAN WITH FLUID COUPLING AND FAN PULLEYS
7. REMOVE AIR CLEANER ASSEMBLY
8. DISCONNECT CABLES
a. Disconnect the accelerator cable.
b. A/T:
Disconnect the throttle cable.
c. w/ Cruise Control:
Disconnect the cruise control actuator cable.
9. DISCONNECT HEATER HOSES
10. DISCONNECT HOSES
a. Disconnect the brake booster vacuum hose.
b. Disconnect the EVAP hose.
c. Disconnect the A.D.D. vacuum hose.
d. Disconnect the fuel return hose.
e. Disconnect the fuel inlet hose.
11. DISCONNECT STARTER WIRE AND CONNECTORS
a. Remove the bolt, and disconnect the ground strap.
b. Remove the 2 nut, and disconnect the positive (+) terminal cable from the battery.
c. Disconnect the 2 starter wire clamps and connector.
d. Remove the nut, and disconnect the wire from the relay block No.2.
12. DISCONNECT GENERATOR WIRE
13. DISCONNECT ENGINE WIRE FROM CABIN
a. Remove the glove compartment door.
b. Remove the lower finish No.2 panel.
c. Disconnect the 5 ECM connectors.
d. Disconnect the 2 cassette connectors (cowl wire x engine wire) and 2 wire clamps from the lower finish panel.
e. Disconnect the engine wire clamp.
f. Disconnect the igniter connector.
g. Disconnect the ground strap.
h. Disconnect the VSV connector for the EVAP.
i. Disconnect the vapor pressure sensor connector.
j. Disconnect the VSV connector for the vapor pressure sensor and clamp.
k. Remove the bolt and wire bracket.
l. Remove the 2 nuts holding the engine wire retainer to the cowl panel, and pull out the engine wire from the cabin.
14. REMOVE ENGINE
a. w/ A/C:
Remove the bolt and disconnect the A/C compressor wire clamp.
b. Install an engine hanger No.2 in the correct direction.
Part No.:
Engine hanger No.2 12282-62030
Bolt 91512-61020
Torque: 40 Nm (400 kgf-cm, 30 ft. lbs.)
c. Attach the engine hoist chain to the 2 engine hangers.
d. Remove the 4 bolts and nuts holding the engine front mounting insulators to the frame.
e. Lift the engine out of the vehicle slowly and carefully.
NOTICE: Make sure the engine is clear of all wiring and hoses.
f. Place the engine assembly onto the stand.
INSTALLATION
1. INSTALL ENGINE ASSEMBLY IN VEHICLE
a. Attach the engine hoist chain to the engine hangers.
b. Lower the engine assembly into the engine compartment.
c. Keep the engine level, and align the RH and LH mountings and body mountings.
d. Attach the RH and LH mounting insulators to the body mountings, and temporarily install the 4 bolts and nuts.
e. Remove the engine chain hoist from the engine.
f. Remove the 2 bolts and engine hanger No.2.
g. w/ A/C:
Install the bolt, and connect the A/C compressor wire.
2. TIGHTEN RH AND LH ENGINE MOUNTING INSULATOR BOLTS AND NUTS
Tighten the 4 bolts and nuts holding the mounting insulators to the body mountings.
Torque: 38 Nm (387 kgf-cm, 28 ft. lbs.)
3. CONNECT ENGINE WIRE TO CABIN
a. Push in the engine wire through the cowl panel.
b. Install the 2 nuts.
c. Install the bolt and bracket.
d. Connect the engine wire clamp.
e. Connect the round strap.
f. Connect the igniter connector.
g. Connect the VSV connector for the EVAP.
h. Connect the vapor pressure sensor connector and clamp.
i. Connect the VSV connector for the vapor pressure sensor and clamp.
j. Connect the 5 connectors to the ECM.
k. Connect the 2 cassette connectors.
l. Install the ECM with the 2 bolts.
m. Install the lower finish No.2 panel.
n. Install the glove compartment door.
4. CONNECT GENERATOR WIRE
5. CONNECT STARTER WIRE AND CONNECTORS
a. Connect the 3 starter wire clamps and connector.
b. Install the 2 nuts, and connect the positive (+) terminal cable to battery.
c. Connect the ground strap with the bolt.
d. Connect wire to the relay block No.2 with the nut.
6. CONNECT HOSES
a. Connect the fuel return hose.
b. Connect the fuel inlet hose.
c. Connect the brake booster vacuum hose.
d. Connect the EVAP hose.
e. Connect the A.D.D. vacuum hose
7. CONNECT HEATER HOSES
8. CONNECT CABLES
a. Connect the accelerator cable.
b. A/T:
Connect the throttle cable.
c. w/ Cruise Control:
Connect the cruise control actuator cable.
9. INSTALL FAN WITH FLUID COUPLING AND FAN PULLEYS
10. INSTALL AIR CLEANER ASSEMBLY
11. INSTALL RADIATOR ASSEMBLY
12. FILL WITH ENGINE OIL
13. FILL WITH ENGINE COOLANT
14. INSTALL ENGINE UNDER COVER
15. INSTALL TRANSMISSION
16. INSTALL HOOD
17. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
18. RECHECK ENGINE COOLANT AND ENGINE OIL LEVELS