Engine: Service and Repair

REMOVAL
1. REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. DRAIN ENGINE OIL
4. DRAIN TRANSMISSION OIL
5. REMOVE HOOD
6. REMOVE RADIATOR
7. REMOVE DRIVE BELT FOR GENERATOR, FAN WITH FLUID COUPLING AND WATER PUMP PULLEY
8. DISCONNECT CABLES:
a. Disconnect the accelerator cable from the throttle body.
b. w/ Cruise Control System: Remove the actuator cover, and disconnect the cruise control cable from the actuator.





9. REMOVE AIR CLEANER ASSEMBLY
a. Disconnect the MAF meter connector.
b. Disconnect the 3 wire clamps and engine wire.
c. Loose in the air cleaner hose clamp.
d. Remove the 3 bolts and the MAF meter, resonator and air cleaner assembly.
10. REMOVE INTAKE AIR CONNECTOR





11. DISCONNECT A/C COMPRESSOR
a. Loose In the idler pulley nut and adjusting bolt, and remove the drive belt.
b. Disconnect the A/C compressor connector.
c. Remove the 4 bolts, and disconnect the compressor from the bracket.

HINT: Put a side the compressor, and suspend it.





12. REMOVE GENERATOR WIRE
a. Disconnect the generator connector.
b. Remove the nut, and disconnect the generator wire and wire clip.





13. DISCONNECT HEATER HOSES
a. Remove the bolt and hose clamp.
b. Disconnect the heater hoses.





14. DISCONNECT HOSES
a. Disconnect the brake booster vacuum hose.
b. Disconnect the EVAP hose.
c. w/ PS: Disconnect the 2 air hoses for PS idle-up.
d. Disconnect the fuel return hose.
e. Disconnect the fuel inlet hose.
15. REMOVE PS PUMP FROM ENGINE, IF EQUIPPED.
16. DISCONNECT ENGINE WIRE FROM CABIN
a. Remove the glove compartment.
b. Remove the lower finish No.2 panel.
c. Disconnect the 4 ECM connectors.
d. Disconnect the 2 cassette connectors (cowl wire to engine wire) and 2 wire clamps from the lower finish panel.





e. Disconnect the ground strap from cowl top panel.
f. Disconnect the 2 engine wire clamps.





g. Remove 2 nuts holding the engine wire retainer to the cowl panel and pull out the engine wire from the cabin.





17. REMOVE No.1 EXHAUST PIPE (WITH TWC)
a. Disconnect the A/F sensor connector.
b. Remove the 2 bolts holding the support bracket to the transmission.
c. Remove the 2 bolts holding the No.1 exhaust pipe to the No.2 c exhaust pipe.
d. Remove the 3 nuts, the No.1 exhaust pipe and 2 gaskets (2RZ- FE) or 3 gaskets (3RZ-FE).





18. M/T: REMOVE SHIFT LEVER ASSEMBLY
a. Remove the shift lever knob.
b. Remove the 4 screws and shift lever boot.
c. Remove the 6 bolts, shift lever assembly and baffle.

NOTICE: Do not lose the washers.

19. REMOVE PROPELLER SHAFT
20. DISCONNECT SPEEDOMETER CABLE

NOTICE: Do not lose the felt protector and washers.





21. M/T: REMOVE CLUTCH RELEASE CYLINDER
a. Remove the 2 bolts, and disconnect the clutch release cylinder from the clutch housing.
b. Remove the bolt and disconnect the clutch line.





22. A/T: REMOVE CROSS SHAFT
Remove the 2 bolts and nut, and disconnect bracket from the transmission.





23. DISCONNECT STARTER WIRE
a. Remove the nut and disconnect the starter wire.
b. Disconnect the starter connector.
c. Remove the bolt and disconnect ground strap.
24. PLACE JACK UNDER TRANSMISSION





25. REMOVE ENGINE REAR MOUNTING BRACKET
Remove the 8 bolts holding the mounting bracket to the mounting insulator and cross member.
26. REMOVE ENGINE WITH TRANSMISSION





a. Install a rear engine hanger in the correct direction.
Part No.:
No.2 engine hanger 12282-75020
Bolt 91512-61020
Torque: 42 Nm (420 kgf-cm, 30 ft. lbs.)





b. Attach the engine hoist chain to the 2 engine hangers.





c. Remove the 4 bolts and nuts holding the engine front mounting insulators to the frame.
d. Lift the engine with transmission out of the vehicle slowly and carefully.

NOTICE: Make sure the engine is clear of all wiring and hoses.

e. Place the engine and transmission assembly onto the stand
27. SEPARATE ENGINE AND TRANSMISSION

INSTALLATION
1. INSTALL TRANSMISSION TO ENGINE
2. INSTALL ENGINE AND TRANSMISSION ASSEMBLY IN VEHICLE





a. Attach the engine hoist chain to the engine hangers.
b. Lower the engine and transmission 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. Jack up and put the transmission onto the frame.
f. Remove the hoist chain.
g. Remove the bolt and rear engine hanger.





3. INSTALL ENGINE REAR MOUNTING BRACKET
Torque:
Bolt A: 18 Nm (183 kgf-cm, 13 ft. lbs.)
Bolt B: 25 Nm (260 kgf-cm, 19 ft. lbs.)
4. 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.)
5. CONNECT STARTER WIRE





6. M/T: INSTALL CLUTCH RELEASE CYLINDER
a. Connect the clutch line with the bolt.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
b. Install the clutch release cylinder with the 2 bolts.
Torque: 13 Nm (130 kgf-cm, 9 ft. lbs.)





7. A/T: INSTALL CROSS SHAFT
Torque:
Bolt: 39 Nm (400 kgf-cm, 29 ft. lbs.)
Nut: 18 Nm (183 kgf-cm, 13 ft. lbs.)
8. CONNECT SPEEDOMETER CABLE
9. INSTALL PROPELLER SHAFT





10. M/T: INSTALL SHIFT LEVER ASSEMBLY
11. INSTALL No.1 EXHAUST PIPE (WITH TWC)
a. Install a new gasket (2RZ-FE) or 2 new gaskets (3RZ-FE) and the No.1 exhaust pipe with new 3 nuts.
Torque: 62 Nm (630 kgf-cm, 46 ft. lbs.)
b. Install the support bracket with the 2 bolts.
Torque: 44 Nm (450 kgf-cm,33 ft. lbs.)
c. Install a new gasket and connect the No.1 exhaust pipe to the No.2 exhaust pipe with the 2 bolts and 2 nuts.
Torque: 48 Nm (490 kgf-cm, 35 ft. lbs.)
d. Connect the A/F sensor connector.
12. CONNECT ENGINE WIRE TO CABIN
13. CONNECT GENERATOR WIRE
14. w/PS: INSTALL PS PUMP
15. 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. w/ PS: Connect the 2 air hoses for PS idle up.
16. CONNECT HEATER HOSES
17. INSTALL A/C COMPRESSOR
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
18. INSTALL INTAKE AIR CONNECTOR
Torque 18 Nm (185 kgf-cm, 13 ft. lbs.)
19. INSTEP AIR CLEANER ASSEMBLY
20. CONNECT CABLES:
a. Connect the throttle cable to the throttle body.
b. w/ Cruise Control System: Connect the cruise control cable to the actuator, and install the actuator cover.
21. INSTALL RADIATOR
22. FILL WITH ENGINE OIL
23. FILL WITH ENGINE COOLANT
24. FILL TRANSMISSION OIL
25. START ENGINE AND CHECK FOR LEAKS
26. INSTALL ENGINE UNDER COVER
27. INSTALL HOOD
28. VEHICLE ROAD TEST
Check for abnormal noise, shock, slippage, and smooth operation.
29. RECHECK ENGINE COOLANT AND ENGINE OIL LEVELS