Engine: Service and Repair

REMOVAL
1. REMOVE BATTERY AND TRAY
2. REMOVE HOOD
3. REMOVE ENGINE FENDER APRON SEALS
4. DRAIN ENGINE COOLANT
5. DRAIN ENGINE OIL
6. REMOVE SUSPENSION UPPER BRACE
7. DISCONNECT ACCELERATOR CABLE
8. REMOVE AIR CLEANER CAP ASSEMBLY AND AIR CLEANER CASE
9. REMOVE CRUISE CONTROL ACTUATOR
10. REMOVE RADIATOR





11. REMOVE FRONT EXHAUST PIPE
a. Remove the 2 bolts holding the support stay to the support bracket.
b. Remove the 2 bolts holding the support bracket to the front frame.
c. Remove the 2 bolts and 2 nuts holding the front exhaust pipe to the center exhaust pipe.
d. Remove the 4 nuts holding the front exhaust pipe to the exhaust manifolds.
e. Remove the front exhaust pipe and 3 gaskets.
12. DISCONNECT CONNECTORS, CABLE, CLAMPS AND HOSES
a. Disconnect the igniter connector on the LH fender apron.
b. Disconnect the noise filter connector on the LH fender apron.
c. Disconnect the generator wire and connector.
d. Disconnect the starter wire and connector.
e. Disconnect the 2 ground strap connectors from the LH fender apron.
f. Disconnect the 2 ground strap connectors from the RH fender apron.
g. Disconnect the DLC1 from the RH fender apron.
h. Disconnect the ground cable from battery body bracket.
i. Disconnect the engine wire protector clamp from the battery body bracket.
j. Disconnect the engine wire clamp from the bracket on the RH fender apron.
k. Disconnect the engine wire clamp from bracket on the fuel filter.
l. Disconnect the brake booster vacuum hose from the air intake chamber.
m. Disconnect the engine coolant reservoir hose from the water outlet.
n. Disconnect the heater hose from the intake manifold.
o. Disconnect the heater hose from the water inlet housing.
p. Disconnect the fuel inlet hose from the fuel filter.

CAUTION: Perform disconnecting operation of the fuel tube connector (quick type) after observing the precautions.

q. Disconnect the purge hose from the pipe on the emission control valve set.
r. Disconnect the 2 vacuum hoses from the vacuum tank for ACIS.





13. DISCONNECT ENGINE WIRE FROM CABIN
a. Remove the No.2 instrument lower panel.
b. Disconnect the 3 ECM connectors.
c. Disconnect the 3 cowl wire connectors from the connectors on the bracket.
d. Disconnect the grommet from the cowl panel, and pull out the engine wire.
14. REMOVE DRIVE SHAFTS
15. M/T only: REMOVE STARTER
16. M/T only: DISCONNECT CLUTCH RELEASE CYLINDER AND ACCUMULATOR WITHOUT DISCONNECTING TUBE





17. DISCONNECT A/C COMPRESSOR FROM ENGINE
a. Disconnect the A/C compressor connector.
b. Remove the drive belt.
c. Remove the 4 bolts, nut and drive belt adjusting bar bracket.
d. Disconnect the A/C compressor from the engine.
18. DISCONNECT TRANSAXLE CONTROL CABLE(S) FROM TRANSAXLE





19. DISCONNECT PS PUMP FROM ENGINE
a. Remove the 2 nuts, and disconnect the PS pressure tube from the No.1 engine hanger.
b. Loosen the 2 bolts, and remove the drive belt.
c. Remove the 2 bolts, and disconnect the PS pump from the engine.
20. DISCONNECT TRANSAXLE FROM LH ENGINE MOUNTING INSULATOR





a. M/T: Remove the 3 bolts holding the transaxle to the mounting insulator.





b. A/T: Remove the 4 bolts holding the transaxle to the mounting insulator.





21. DISCONNECT REAR ENGINE MOUNTING BRACKET FROM FRONT FRAME
a. Remove the 2 hole plugs.
b. Remove the 4 nuts holding the front frame to the mounting bracket.





22. REMOVE ENGINE MOUNTING ABSORBER
Remove the 4 bolts and mounting absorber.





23. DISCONNECT FRONT ENGINE MOUNTING INSULATOR FROM FRONT FRAME
Remove the 3 bolts holding the mounting insulator to the front frame.





24. ATTACH ENGINE SLING DEVICE TO ENGINE HANGERS
a. Install the No.2 engine hanger in the correct direction.
Part No.:
No.2 engine hanger 12282-20020
Bolt 91621-60822
Torque: 19.5 Nm (200 kgf-cm, 14 ft. lbs.)
b. Attach the sling device to the engine hangers.

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





25. REMOVE RH ENGINE MOUNTING STAY
Remove the 3 bolts, ground strap and RH engine mounting stay.





26. M/T only: REMOVE NO.2 RH ENGINE MOUNTING STAY
Remove the 2 bolts and No.2 RH engine mounting stay.





27. REMOVE ENGINE MOVING CONTROL ROD AND NO.2 RH ENGINE MOUNTING BRACKET
Remove the 3 bolts, control rod and mounting bracket.





28. REMOVE ENGINE AND TRANSAXLE ASSEMBLY FROM VEHICLE
a. Lift the engine out of the vehicle slowly and carefully.

NOTICE:
^ Be careful not to hit the PNP switch.
^ Make sure the engine is clear of all wiring, hoses and cables.

b. Place the engine and transaxle assembly onto the stand.
29. REMOVE FRONT ENGINE MOUNTING INSULATOR FROM ENGINE
Remove the 4 bolts and mounting insulator.
30. REMOVE REAR ENGINE MOUNTING INSULATOR AND BRACKET ASSEMBLY FROM ENGINE
Remove the 4 bolts, the mounting insulator and bracket assembly.
31. SEPARATE ENGINE AND TRANSAXLE

INSTALLATION
1. ASSEMBLE ENGINE AND TRANSAXLE AM
2. INSTALL REAR ENGINE MOUNTING INSULATOR
Install the mounting insulator with the 4 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
3. INSTALL FRONT ENGINE MOUNTING INSULATOR
Install the mounting insulator with the 4 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)





4. 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 park/neutral position switch.

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





5. INSTALL NO.2 ENGINE MOUNTING BRACKET AND ENGINE MOVING CONTROL ROD
Install the mounting moving control rod and No.2 engine mounting bracket with the 3 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)





6. M/T only: INSTALL NO.2 RH ENGINE MOUNTING STAY
Install the No.2 RH engine mounting stay with the 2 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)





7. INSTALL RH ENGINE MOUNTING STAY
Install the RH mounting stay with the 3 bolts.
Torque: 32 Nm (320 kgf-cm, 23 ft. lbs.)





8. CONNECT FRONT ENGINE MOUNTING INSULATOR
Connect the mounting insulator with the 3 bolts.
Torque: 44 Nm (450 kgf-cm, 32 ft. lbs.) for silver color bolt 66 Nm (670 kgf-cm, 48 ft. lbs.) for green color bolt





9. INSTALL ENGINE MOUNTING ABSORBER
Install the engine mounting absorber with the 4 bolts.
Torque: 48 Nm (490 kgf-cm, 35 ft. lbs.)





10. CONNECT REAR ENGINE MOUNTING INSULATOR
a. Connect the mounting insulator with the 4 nuts.
Torque: 66 Nm (670 kgf-cm, 48 ft. lbs.)
b. Install the 2 hole plugs.
11. CONNECT LH ENGINE MOUNTING INSULATOR





a. M/T: Connect the mounting insulator with the 3 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)





b. A/T: Connect the mounting insulator with the 4 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
12. REMOVE ENGINE SLING DEVICE
13. CONNECT TRANSAXLE CONTROL CABLE(S) TO TRANSAXLE





14. INSTALL PS PUMP
a. Install the PS pump with the 2 bolts.
Torque: 43 Nm (440 kgf-cm, 31 ft. lbs.)
b. Install the drive belt.
c. Connect the PS pressure tube with the 2 nuts.





15. INSTALL A/C COMPRESSOR
a. Install the A/C compressor and drive belt adjusting bar bracket with the 4 bolts and nut.
Torque:
Bolt A: 25 Nm (250 kgf-cm, 18 ft. lbs.)
Bolt B: 18 Nm (185 kgf-cm, 13 ft. lbs.)
Nut C: 25 Nm (250 kgf-cm, 18 ft. lbs.)
b. Install the drive belt.
c. Connect the A/C compressor connector.
16. M/T only: INSTALL CLUTCH RELEASE CYLINDER AND ACCUMULATOR
17. M/T only: INSTALL STARTER
18. INSTALL DRIVE SHAFTS





19. CONNECT ENGINE WIRE TO CABIN
a. Push in the engine wire through the cowl panel. Install the grommet.
b. Connect the 3 engine ECM connectors.
c. Connect the 3 cowl wire connectors to the connectors on the bracket.
d. Install the No.2 instrument lower panel.
20. CONNECT CONNECTORS, CABLE, CLAMPS AND HOSES
a. Connect the igniter connector on the LH fender apron.
b. Connect the noise filter connector on the LH fender apron.
c. Connect the generator connector and wire.
d. Connect the starter connector and wire.
e. Connect the 2 ground strap connectors to the RH fender apron.
f. Connect the 2 ground strap connectors to the LH fender apron.
g. Connect the DLC1 to the RH fender apron.
h. Connect the ground cable to the battery body bracket.
i. Connect the engine wire protector clamp to the battery body bracket.
Connect the engine wire clamp to the bracket on the RH fender apron.
k. Connect the engine wire clamp to the bracket on the fuel filter..
l. Connect the brake booster vacuum hose to the air intake chamber
m. Connect the engine coolant reservoir hose to the water outlet.
n. Connect the heater hose to the intake manifold.
o. Connect the heater hose to the water inlet housing.
p. Connect the fuel inlet hose to the fuel filter.

CAUTION: Perform connecting operations of the fuel tube connector (quick type) after observing the precautions.

q. Connect the purge hose to the pipe on the emission control valve set.
r. Connect the 2 vacuum hoses to the vacuum tank for ACIS.





21. INSTALL FRONT EXHAUST PIPE
a. Temporarily install 3 new gaskets and the front exhaust pipe with the 2 bolts and 6 nuts.
b. Tighten the 4 nuts holding the exhaust manifolds to the front exhaust pipe.
Torque: 62 Nm (630 kgf-cm, 46 ft. lbs.)
c. Tighten the 2 bolts and 2 nuts holding the front exhaust pipe to the center exhaust pipe.
Torque: 56 Nm (570 kgf-cm, 41 ft. lbs.)
d. Install the bracket with the 2 bolts.
Torque: 33 Nm (330 kgf-cm, 24 ft. lbs.)
e. Install the support stay with the 2 bolts.
Torque: 33 Nm (330 kgf-cm, 24 ft. lbs.)
22. INSTALL RADIATOR)
23. INSTALL CRUISE CONTROL ACTUATOR
24. INSTALL AIR CLEANER CAP ASSEMBLY AND AIR CLEANER CASE
25. INSTALL SUSPENSION UPPER BRACE
Install the suspension upper brace with the 4 nuts.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
26. CONNECT ACCELERATOR CABLE
27. INSTALL ENGINE FENDER APRON SEALS
28. INSTALL BATTERY TRAY AND BATTERY
29. INSTALL HOOD
30. FILL ENGINE WITH OIL
31. FILL WITH ENGINE COOLANT
32. START ENGINE AND CHECK FOR LEAKS
33. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
34. RECHECK ENGINE COOLANT AND OIL LEVELS