Engine: Service and Repair

ECM (Passenger Compartment):

REMOVAL
1. REMOVE HOOD
2. REMOVE ENGINE UNDER COVERS
3. DRAIN ENGINE COOLANT
4. DRAIN ENGINE OIL
5. REMOVE V-BANK COVER
6. REMOVE BATTERY
7. REMOVE AIR CLEANER CAP AND INTAKE AIR CONNECTOR PIPE ASSEMBLY
8. REMOVE RADIATOR RESERVOIR
a. Disconnect the clamp on the wire from the reservoir.
b. Disconnect the reservoir hose from the radiator.
c. Remove the 2 bolts, reservoir and grommet.
9. REMOVE RADIATOR AND FAN SHROUD
a. Disconnect the upper radiator hose from the front water bypass joint.
b. Remove the 2 nuts, and disconnect the 2 clamps on the A/C discharge tube from the bracket.
c. Remove the 2 bolts, and disconnect the 2 brackets on the wire from the radiator.
d. Remove the 3 bolts, and disconnect the fan shroud from the radiator.
e. Remove the lower radiator hose.
f. Disconnect the 2 A/T oil cooler hoses from the radiator.
g. Remove the 2 bolts, 2 nuts, 2 support collars and radiator.
h. Remove the fan shroud.
10. REMOVE GENERATOR DRIVE BELT, FAN, FLUID COUPLING AND FAN PULLEY
a. Loosen the 4 nuts holding the fluid coupling to the fan bracket.
b. Remove the generator drive belt.
c. Remove the 4 nuts, the fan, fluid coupling assembly and fan pulley.
11. DISCONNECT ENGINE WIRE FROM CABIN
a. Remove the glove compartment door.
b. Remove the lower No.2 panel.
c. Disconnect the 3 connectors from the ECM.
d. Remove the 3 screws, and disconnect the ECM from the body bracket.
e. Disconnect the 3 wire harness connectors.
12. DISCONNECT HOSES, WIRES, CONNECTORS, CLAMPS, GROMMET AND CABLES
a. Disconnect the accelerator cable from engine.
b. Disconnect the 2 PS air hoses from hose clamp on No.3 RH timing belt cover.
c. Disconnect the generator wire.
d. Disconnect the generator connector.
e. Disconnect the hose clamp for PS air hose.
f. Disconnect the PS air hose from upper intake manifold.
g. Disconnect the 2 heater hoses.
h. Disconnect the engine wire clamp from bracket on cowl panel.
i. Disconnect the engine wire grommet from cowl panel.
j. Disconnect the ground strap connector.
k. Disconnect the fuel main hose and clamps.
l. Disconnect the fuel return hose and clamp.
m. Disconnect the air inlet hose from charcoal canister.
n. Disconnect the EVAP hose from charcoal canister.
o. Disconnect the engine wire from clamp on right fender apron.
p. Disconnect the clamp on battery negative (-) cable from relay box.
q. Disconnect the battery negative (-) cable from right fender apron.
r. Disconnect the battery positive (+) terminal cable.
13. REMOVE SHIFT LEVER ASSEMBLY AND TRANSFER SHIFT LEVER ASSEMBLY
a. Remove the transfer shift lever knob.
b. Remove the upper console panel.





c. Remove the shift lever assembly.
1. Disconnect the connector.
2. Remove the 6 bolts.
3. Remove the clip and plate washer, and disconnect the transmission control rod from the shift lever assembly.
4. Remove the shift lever assembly.
d. Remove the 4 bolts and transfer shift lever boot.





e. Remove the transfer shift lever assembly.
1. Remove the clip, plate washer and wave washer, and disconnect the transfer rod from the shift lever.
2. Remove the bushing.
3. Remove the 4 bolts, shift lever and gasket.
14. REMOVE FRONT EXHAUST PIPES
15. REMOVE PROPELLER SHAFT
16. REMOVE STABILIZER BAR





17. DISCONNECT A/C COMPRESSOR FROM ENGINE
a. Disconnect the A/C compressor connector.
b. Remove the 3 bolts, and disconnect the A/C compressor from the engine.

HINT: Suspend the A/C compressor securely.

18. DISCONNECT PS PUMP FROM ENGINE
Remove the 3 bolts, and disconnect the PS pump from the engine.

HINT: Suspend the PS pump securely.

19. REMOVE ENGINE AND TRANSMISSION ASSEMBLY FROM VEHICLE
a. Attach the engine chain hoist to the engine hangers.





b. Remove the 2 nuts and 4 bolts holding the engine mounting brackets to the frame brackets.
c. Remove the 3 bolts and transfer case protector.





d. Remove the 8 bolts, 2 nuts and frame crossmember.





e. Lift the engine out of the vehicle slowly and carefully.

HINT: Make sure the engine is clear of all wiring, hoses and cables.

f. Place the engine and transmission assembly onto the stand.
20. DISCONNECT ENGINE WIRE FROM TRANSMISSION
a. Disconnect the 5 connectors.
b. Disconnect the 2 wire clamps.
21. REMOVE OIL DIPSTICK GUIDE AND DIPSTICK FOR TRANSMISSION
a. Disconnect the 2 breather hoses from the dipstick guide.
b. Remove the 2 bolts.
c. Pull out the dipstick guide and dipstick from the dipstick tube of transmission.
d. Remove the O-ring from the dipstick guide.
22. REMOVE OIL COOLER PIPES FOR TRANSMISSION
a. Remove the 3 bolts and 3 stays.
b. Loosen the 2 union nuts, and remove the 2 oil cooler pipes.
23. REMOVE TORQUE CONVERTER CLUTCH BOLTS





a. Remove the 2 bolts and flywheel housing under cover.





b. Turn the crankshaft pulley bolt to gain access to each bolt.
c. Hold the crankshaft pulley bolt with a wrench, and remove the 6 bolts.





24. REMOVE TRANSMISSION
a. Remove the 10 bolts.
b. Remove the transmission together with the torque converter clutch from the engine.





25. REMOVE DRIVE PLATE
Remove the 8 bolts, front spacer, drive plate and rear spacer.

INSTALLATION
1. INSTALL DRIVE PLATE

HINT:
- The mounting bolts are tightened in 2 progressive steps (steps (c) and (e)).
- If any one of the mounting bolts is broken or deformed, replace it.





a. Apply adhesive to 2 or 3 threads of the mounting bolt end.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent





b. Install the front spacer, drive plate and rear spacer on the crankshaft.
c. Install and uniformly tighten the 8 mounting bolts in several passes, in the sequence shown.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
If any one of the mounting bolts does not meet the torque specification, replace the mounting bolt.





d. Mark the mounting bolt with paint.
e. Retighten the mounting bolts by 90° in the numerical order shown.
f. Check that the painted mark is now at a 90° angle to (e).





2. INSTALL TRANSMISSION TO ENGINE
a. Check the torque converter clutch installation.
b. Attach the transmission to the engine.
c. Install the ground strap and 10 bolts.
Torque:
37 Nm (380 kgf-cm, 27 ft. lbs.) for 14 mm head
72 Nm (730 kgf-cm, 53 ft. lbs.) for 17 mm head
3. INSTALL TORQUE CONVERTER CLUTCH BOLTS





a. Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent





b. Hold the crankshaft pulley bolt with a wrench, and install the 6 bolts evenly.
Torque: 48 Nm (490 kgf-cm, 35 ft. lbs.)

HINT: First install the black colored bolt, install the other bolts.





c. Install the flywheel housing under cover with the 2 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
4. INSTALL OIL COOLER PIPE FOR TRANSMISSION
5. INSTALL OIL DIPSTICK GUIDE AND DIPSTICK FOR TRANSMISSION
a. Install a new O-ring to the dipstick guide.
b. Apply soapy water to the O-ring.
c. Connect the dipstick guide end to the dipstick tube of the oil pan.
d. Install the dipstick guide with the bolt.
e. Install the dipstick.
f. Connect the 2 breather hoses to the dipstick guide.
6. CONNECT ENGINE WIRE TO TRANSMISSION
a. Connect the 5 connectors.
b. Connect the 2 wire clamps.
7. INSTALL ENGINE AND TRANSMISSION ASSEMBLY IN VEHICLE
a. Attach the engine chain hoist to the engine hangers.





b. Slowly lower the engine and transmission assembly into the engine compartment.
c. Attach the engine mounting brackets to the frame brackets.





d. Keep the engine level with a jack.





e. Install the frame crossmember with the 8 bolts and 4 nuts.
Torque:
50 Nm (510 kgf-cm, 37 ft. lbs.) for bolts
74 Nm (750 kgf-cm, 55 ft. lbs.) for nuts
f. Install the transfer case protector with the 3 bolts.





g. Install the 2 nuts and 4 bolts holding the engine mounting brackets to the frame brackets.
Torque: 30 Nm (310 kgf-cm, 22 ft lbs.)
h. Remove the engine chain hoist.
8. INSTALL PS PUMP
Install the PS pump with the 3 bolts.
Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)





9. INSTALL A/C COMPRESSOR
a. Install the A/C compressor with the 3 bolts.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
b. Connect the A/C compressor connector.
10. INSTALL STABILIZER BAR
11. INSTALL PROPELLER SHAFT
12. INSTALL FRONT EXHAUST PIPES
13. INSTALL SHIFT LEVER ASSEMBLY AND TRANSFER SHIFT LEVER ASSEMBLY





a. Install the transfer shift lever.
1. Install a new gasket and the shift lever with the 4 bolts.
2. Connect the transfer shift lever rod to the shift lever with the bushing, wave washer, plate washer and clip.
b. Install the transfer shift lever boot with the 4 bolts.





c. Install the shift lever assembly.
1. Connect the transmission control rod to the shift lever assembly with the plate washer and clip.
2. Install the shift lever assembly with the 6 bolts.
3. Connect the connector.
d. Install the console upper cover.
e. Install the transfer shift lever knob.
14. CONNECT HOSES, WIRES, CONNECTORS, CLAMPS, GROMMET AND CABLES
a. Connect the accelerator cable to engine.
b. Connect the 2 PS air hoses to hose clamp on No.3 RH timing belt cover.
c. Connect the generator wire.
d. Connect the generator connector.
e. Connect the hose clamp for PS air hose.
f. Connect the PS air hose to upper intake manifold.
g. Connect the 2 heater hoses.
h. Connect the engine wire clamp to bracket on cowl panel.
i. Connect the engine wire grommet to cowl panel.
j. Connect the ground strap connector.
k. Connect the fuel main hose and clamps.
l. Connect the fuel return hose and clamp.
m. Connect the air inlet hose to charcoal canister.
n. Connect the EVAP hose to charcoal canister.
o. Connect the engine wire to clamp on right fender apron.
p. Connect the clamp on battery negative (-) cable to relay box.
q. Connect the battery negative (-) cable to right fender apron.
r. Connect the battery positive (+) terminal cable.
15. CONNECT ENGINE WIRE TO CABIN
a. Connect the 3 wire harness connectors.
b. Install the ECM with the 3 screws.
c. Connect the 3 connectors to the ECM.
d. Install the glove compartment door.
e. Install the lower No.2 panel.
16. INSTALL FAN PULLEY, FAN, FLUID COUPLING AND GENERATOR DRIVE BELT
a. Temporarily install the fan pulley, the fan and fluid coupling assembly with the 4 nuts.
b. Install the generator drive belt.
c. Tighten the 4 nuts holding the fluid coupling to the fan bracket.
17. INSTALL RADIATOR AND FAN SHROUD
a. Place the fan shroud in the installation position.
b. Install the radiator with the 2 support collars, 2 nuts and 2 bolts.
c. Connect the 2 A/T oil cooler hoses to the radiator.
d. Install the lower radiator hose.
e. Attach the lower side of the fan shroud to the brackets of the radiator, and install the fan shroud with the 2 bolts.
f. Install the 2 brackets on the wire to the radiator with the 2 bolts.
g. Install the 2 clamps on the A/C discharge tube to the brackets on the wire with the 2 nuts.
h. Connect the upper radiator hose to the front water bypass joint.
18. INSTALL RADIATOR RESERVOIR
a. Install the grommet to the reservoir.
b. Attach the lower side of the reservoir to the fan shroud.
c. Install the reservoir with the 2 bolts.
d. Connect the reservoir hose to the radiator.
e. Install the clamp on the wire to the reservoir.
19. INSTALL AIR CLEANER CAP AND INTAKE AIR CONNECTOR PIPE ASSEMBLY
20. INSTALL BATTERY
21. FILL WITH ENGINE COOLANT
22. FILL WITH ENGINE OIL
23. START ENGINE AND CHECK FOR LEAKS
24. INSTALL V-BANK COVER
25. INSTALL ENGINE UNDER COVERS
26. INSTALL HOOD
27. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
28. RECHECK ENGINE COOLANT AND OIL LEVELS