Engine: Service and Repair

REMOVAL
1. REMOVE ENGINE HOOD
2. REMOVE ENGINE UNDER COVER
3. DRAIN ENGINE COOLANT
4. REMOVE RADIATOR ASSEMBLY
5. REMOVE THROTTLE BODY COVER
6. REMOVE AIR CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY
a. Disconnect the MAP meter connector.
b. Loosen the 3 bolts, and remove the air cleaner case.
c. W/A/C: Remove the suction hose from the intake air connector.
d. Disconnect the PS air hose, air inlet hose for EVAP, PCV hose and MAF meter wire from the air intake connector.
e. Disconnect the intake air connector from the throttle body.
7. DISCONNECT BATTERY CABLES
a. Disconnect the clamp on battery negative (-) cable from the No.2 relay box.
b. Disconnect the battery positive (+) terminal cable.
c. Disconnect battery negative (-) cable from the left fender apron.
8. REMOVE DRIVE BELT, FAN, FLUID COUPLING AND FAN PULLEY
a. Loosen the 4 nuts holding the fluid coupling to the fan bracket.
b. Remove the drive belt.
c. Remove the 4 nuts, the fan, fluid coupling assembly and fan pulley.
9. DISCONNECT ENGINE WIRE FROM CABIN
a. Remove the glove compartment door.
b. Remove the lower No.2 panel.
c. Remove the 3 screws, and disconnect the ECM from the body bracket.
d. Disconnect the 3 wire harness connectors from the ECU.
e. Disconnect the 2 wire harness connectors (cassette connector).





f. Disconnect the engine wire from the engine wire bracket and remove the bolt, 2 nuts and bracket.
g. Pull out the engine wire from the cowl panel.
10. DISCONNECT HOSES, WIRES, CONNECTORS, CLAMPS, GROMMET AND CABLES
a. Disconnect the accelerator cable from the engine.
b. Disconnect the 2 PS air hoses from hose clamp on the No.3 RH timing belt cover.
c. Disconnect the generator wire.
d. Disconnect the generator connector.
e. Disconnect the hose clamp for the PS air hose.
f. Disconnect the PS air hose from the upper intake manifold.
g. Disconnect the 2 heater hoses.
h. Disconnect the ground strap from the cowl panel.
i. Disconnect the fuel inlet hose and clamps.
j. Disconnect the fuel return hose and clamp.
k. Disconnect the air inlet hose from the charcoal canister.
l. Disconnect the EVAP hose from the charcoal canister.
m. w/o Hydraulic brake booster: Disconnect the brake booster tube.
11. REMOVE FRONT EXHAUST PIPES
12. REMOVE PROPELLER SHAFT
13. REMOVE FRONT STABILIZER BAR
14. DISCONNECT POWER STEERING GEAR PIPES
Disconnect the pressure feed tube, turn tube and pressure tubes from the PS gear assembly.





15. REMOVE TRANSMISSION CONTROL CABLE
a. Remove the 2 bolts and control cable bracket from the transmission.
b. Remove the control cable from the control shift lever.





16. w/A/C: 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.





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

HINT: Suspend the PS pump securely.





18. REMOVE ENGINE MOUNTING BRACKETS
a. Attach the engine chain hoist to the engine hangers.
b. Remove the 4 nuts and 4 bolts holding the engine mounting brackets to the frame brackets.
19. PLACE JACK UNDER TRANSMISSION
20. REMOVE ENGINE REAR MOUNTING BRACKET





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





b. Remove the 4 bolts and engine rear mounting bracket from the transmission.





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

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

b. Place the engine and transmission assembly onto the stand.
22. DISCONNECT ENGINE WIRE FROM TRANSMISSION
a. Disconnect the 5 connectors.
b. Disconnect the 2 wire clamps.
23. 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.
24. 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.
25. REMOVE TORQUE CONVERTER CLUTCH BOLTS





a. Remove the bolt 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.





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





27. 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 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 bolt.
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.
8. INSTALL ENGINE REAR MOUNTING BRACKET





a. Install the engine rear mounting bracket to the transmission with the 4 bolts.
Torque: 65 Nm (663 kgf-cm, 48 ft. lbs.)





b. Install the frame crossmember with the 8 bolts and 4 nuts.
Torque:
A: 18 Nm (183 kgf-cm, 13 ft. lbs.) for bolts
B: 72 Nm (730 kgf-cm, 53 ft. lbs.) for nuts





9. INSTALL ENGINE MOUNTING BRACKETS
a. Install the engine mounting brackets to the frame brackets with the 2 nuts and 4 bolts.
Torque: 38 Nm (388 kgf-cm, 28 ft. lbs.)
b. Remove the engine chain hoist.





10. INSTALL PS PUMP
Install the PS pump with the 3 bolts.
Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)





11. w/A/C: 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.





12. INSTALL TRANSMISSION CONTROL CABLE
a. Install the control cable to the control shift lever.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)
b. Install the control cable bracket to the transmission with the 2 bolts.
13. CONNECT POWER STEERING GEAR PIPES
Connect the pressure feed tube, turn tube and turn pressure tubes to the PS gear assembly.
14. INSTALL FRONT STABILIZER BAR
15. INSTALL PROPELLER SHAFT
16. INSTALL FRONT EXHAUST PIPES
17. CONNECT HOSES, WIRES, CONNECTORS, CLAMPS, GROMMET AND CABLES
a. Connect the accelerator cable to the engine.
b. Connect the 2 PS air hoses to hose clamp on the No.3 RH timing belt cover.
c. Connect the generator wire.
d. Connect the generator connector.
e. Connect the hose clamp for the PS air hose.
f. Connect the PS air hose to the upper intake manifold.
g. Connect the 2 heater hoses.
h. Connect the ground strap connector.
i. Connect the fuel inlet hose and clamps.
j. Connect the fuel return hose and clamp.
k. Connect the air inlet hose to the charcoal canister.
l. Connect the EVAP hose to the charcoal canister.
m. Connect the brake booster tube.





18. CONNECT ENGINE WIRE TO CABIN
a. Push into the engine wire through the cowl panel.
b. Install the engine wire bracket with the 2 nuts and bolt and connect the engine wire to the bracket.
c. Connect the 2 wire harness connectors (cassette connector).
d. Connect the 3 connectors to the ECM.
e. Install the ECM with the 3 screws.
f. Install the lower No.2 panel.
g. Install the glove compartment door.
19. INSTALL FAN PULLEY, FAN, FLUID COUPLING AND DRIVE BELT
a. Temporarily install the fan pulley, the fan and fluid coupling assembly with the 4 nuts.
b. Install the drive belt.
c. Tighten the 4 nuts holding the fluid coupling to the fan bracket.
20. INSTALL BATTERY CABLES
a. Connect the clamp on battery negative (-) cable to No.2 relay box.
b. Connect the battery positive (+) terminal cable.
c. Connect the battery negative cable to the left fender apron.
21. INSTALL AIR CLEANER AND INTAKE AIR CONNECTOR ASSEMBLY
a. Install the air cleaner with the 3 bolt.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
b. Connect the intake air connector to the throttle body.
c. Connect the MAP meter connector.
d. w/A/C:
Install the suction hose to the intake air connector.
e. Connect the PS air hose, air inlet hose for EVAP, PCV hose and MAP meter wire to the air intake connector.
22. INSTALL THROTTLE BODY COVER
23. INSTALL RADIATOR ASSEMBLY
24. FILL WITH ENGINE COOLANT
25. FILL WITH ENGINE OIL
26. START ENGINE AND CHECK FOR LEAKS
27. INSTALL ENGINE UNDER COVER
28. INSTALL HOOD
29. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
30. RECHECK ENGINE COOLANT AND OIL LEVELS