Engine: Service and Repair

ENGINE REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY

CAUTION (w/ Airbag): Work must be started after approx. 30 seconds or longer from the time the ignition switch is turned to the LOCK position and the negative (-) terminal cable is disconnected from the battery.

2 REMOVE BATTERY AND TRAY
3. REMOVE HOOD
4. REMOVE ENGINE UNDER COVER
5. DRAIN ENGINE COOLANT
6. DRAIN ENGINE OIL
7. DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY
8. (A/T) DISCONNECT THROTTLE CABLE FROM THROTTLE BODY

9. REMOVE AIR CLEANER ASSEMBLY, RESONATOR AND AIR CLEANER HOSE
(a) Disconnect the air intake temperature sensor connector.
(b) Disconnect the cruise control actuator cable from the clamp on the resonator and air cleaner.
(c) Loosen the air cleaner hose clamp bolt.
(d) Disconnect the four air cleaner cap clips.
(e) Disconnect the air cleaner hose from the throttle body, and remove the air cleaner cap together with the resonator and air cleaner hose.
(f) Remove the element.
(g) Remove the three bolts and air cleaner case.

10. (w/ CRUISE CONTROL SYSTEM) REMOVE CRUISE CONTROL ACTUATOR
(a) Remove the actuator cover.
(b) Disconnect the actuator connector.
(c) Remove the three bolts, and disconnect the actuator with the bracket.

11. DISCONNECT GROUND STRAP FROM BATTERY CARRIER
12. REMOVE RADIATOR

13. DISCONNECT COOLANT RESERVOIR HOSE
- Remove the bolt and disconnect the reservoir hose.

14. REMOVE WASHER TANK
(a) Remove the three washer tank mounting bolts.
(b) Disconnect the connector and hose, and remove the washer tank.

15. DISCONNECT WIRES AND CONNECTORS

(a) Remove the engine relay box, and disconnect the three connectors.
(b) Two connectors from LH fender apron

(f) Data link connector 1
(g) (w/ A/C) A/C magnet switch connector
(h) Ground strap from RH fender apron
(i) Vacuum sensor connector
(j) (M/T) Back-up light switch connector
(k) (M/T) Speed sensor connector

16. DISCONNECT HEATER HOSES
17. DISCONNECT FUEL RETURN HOSE

CAUTION: Catch leaking fuel in a container.

18. DISCONNECT FUEL INLET HOSE

CAUTION: Catch leaking fuel in a container.

19. (M/T) REMOVE STARTER

20. (M/T) REMOVE CLUTCH RELEASE CYLINDER WITHOUT DISCONNECTING TUBE
- Remove the four bolts, release cylinder and tube from the transaxle.

21. DISCONNECT TRANSAXLE CONTROL CABLE(S) FROM TRANSAXLE

22. DISCONNECT VACUUM HOSES
(a) Vacuum sensor hose from air intake chamber
(b) Brake booster vacuum hose from air intake chamber
(c) Charcoal canister vacuum hose.

23. DISCONNECT ENGINE WIRE FROM CABIN
(a) Remove the under cover.
(b) Remove the lower instrument panel.
(c) Remove the glove compartment door.
(d) Remove the glove compartment.
(e) Disconnect the following connectors:
(1) Two FCM connectors
(2) Four cowl wire connector

(f) Remove the two nuts, and pull out the engine wire from the cowl panel.

24. (w/ A/C) REMOVE A/C COMPRESSOR WITHOUT DISCONNECTING HOSES
(a) Disconnect the A/C compressor connector.
(b) Remove the drive belt.
(c) Remove the three bolts. and disconnect the A/C compressor.

HINT: Put aside the compressor, and suspend it from the radiator support.

25. DISCONNECT FRONT EXHAUST PIPE
(a) Loosen the two bolts, and disconnect the bracket.
(b) Using a 14 mm deep socket wrench, remove the three nuts holding the front exhaust pipe to exhaust manifold (three-way catalytic converter (front)).
(c) Disconnect the front exhaust pipe and gaskets.

26. REMOVE DRIVE SHAFTS

27. REMOVE PS PUMP WITHOUT DISCONNECTING HOSES
(a) Disconnect the two air hoses from the air pipe.
(b) Remove the PS drive belt.
(c) Remove the two bolts, and disconnect the PS pump from the engine.

HINT: Put aside the pump and suspend it to the cowl with a string.

28. DISCONNECT LH ENGINE MOUNTING INSULATOR

(M/T) Remove the three bolts, and disconnect the mounting insulator.

(A/T) Remove the four bolts, and disconnect the mounting insulator.

29. DISCONNECT RR ENGINE MOUNTING INSULATOR
(a) Remove the hole plugs.
(b) Remove the three nuts, and disconnect the mounting insulator.

30. DISCONNECT FR ENGINE MOUNTING INSULATOR
- Remove the three bolts, and disconnect the mounting insulator.

31. ATTACH ENGINE SLING DEVICE TO ENGINE HANGERS

32. REMOVE ENGINE MOVING CONTROL ROD
- Remove the three bolts and control rod

33. 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 PS gear housing or park/neutral position switch (A/T).

(b) Make sure the engine is clear of all wiring, hoses and cables.
(c) Place the engine and transaxle assembly onto the stand.

34. (A/T) REMOVE STARTER
35. SEPARATE ENGINE AND TRANSAXLE

36. REMOVE NO.2 RH ENGINE MOUNTING BRACKET
- Remove the three bolts and engine mounting bracket.

37. REMOVE FR ENGINE MOUNTING INSULATOR
(a) Remove the bolt, nut and manifold stay.
(b) Remove the four bolts and mounting insulator.

38. REMOVE RR ENGINE MOUNTING INSULATOR
- Remove the four bolts and mounting insulator.

ENGINE INSTALLATION

1. INSTALL RR ENGINE MOUNTING INSULATOR
- Install the mounting insulator with the four bolts.
Torque: 77 N.m (790 kgf.cm, 57 ft.lbf)

2. INSTALL FR ENGINE MOUNTING INSULATOR
(a) Install the mounting insulator with the four bolts.
Torque: 77 Nm (790 kgf.cm, 57 ft.lbf)

(b) Install the manifold stay with the bolt and nut.
Torque: 42 N.m (425 kgf.cm. 31 ft.lbf)

3. INSTALL NO.2 ENGINE MOUNTING BRACKET

(a) Temporarily install the No.2 engine mounting bracket with the two bolts.
(b) Install the remaining bolt.

(c) Tighten the three bolts in the sequence shown.
Torque: 52 N.m (530 kgf.cm, 38 ft.lbf)

4. ASSEMBLE ENGINE AND TRANSAXLE
5. (A/T) INSTALL STARTER
6. 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 PS gear housing or park/neutral position switch (A/T).

(a) Temporarily install the engine moving control rod with the three bolts in the sequence shown.

(b) Tighten the three bolts in the sequence shown.
Torque: 64 N.m (850 kgf.cm, 47 ft.lbf)

8. CONNECT FR ENGINE MOUNTING INSULATOR
- Connect the mounting insulator with the three bolts.
Torque: 80 N.m (820 kgf.cm, 59 ft.lbf)

9. CONNECT RR ENGINE MOUNTING INSULATOR
(a) Connect the mounting insulator with the three nuts.
Torque: 66 N.m (670 kgf.cm, 48 ft.lbf)
(b) Install the hole plugs.

10. CONNECT LH ENGINE MOUNTING INSULATOR

(M/T) Connect the mounting insulator with the three bolts.
Torque: 64 N.m (650 kgf.cm. 47 ft.lbf)

(A/T) Connect the mounting insulator with the four bolts.
Torque: 64 N.m (650 kgf.cm. 47 ft.lbf)

11. REMOVE ENGINE SLING DEVICE

12. INSTALL PS PUMP
(a) Install the PS pump with the two bolts.
Torque: 43 N.m (440 kgf.cm, 31 ft.lbf)
(b) Install the drive belt.
(c) Connect the two air hoses to the air pipe.

13. INSTALL DRIVE SHAFTS

14. CONNECT FRONT EXHAUST PIPE
(a) Place a new gasket on the front exhaust pipe.
(b) Using a 14 mm deep socket wrench, install the three new nuts holding the front exhaust pipe to the exhaust manifold (three-way catalytic converter (front).
Torque: 62 N.m (630 kgf.cm. 46 ft.lbf)
(c) Install the bracket with the two bolts.

15. (w/ A/C) INSTALL A/C COMPRESSOR
(a) Install the compressor with the three bolts.
Torque: 27 N.m (280 kgf.cm. 20 ft.lbf)

(b) Install the drive belt.
(c) Connect the A/C compressor connector.

16. CONNECT ENGINE WIRE TO CABIN
(a) Push in the engine wire through the cowl panel. Install the two nuts.
(b) Connect the following connectors:

(1) Two FCM connectors
(2) Four cowl wire connectors

(c) Install the glove compartment.
(d) Install the glove compartment door.
(e) Install the lower instrument panel.
(f) Install the under cover.

17. CONNECT VACUUM HOSES
(a) Vacuum sensor hose to air intake chamber
(b) Brake booster vacuum hose to air intake chamber
(c) Charcoal canister vacuum hose

18. CONNECT TRANSAXLE CONTROL CABLE(S) TO TRANSAXLE

19. (M/T) INSTALL CLUTCH RELEASE CYLINDER
- Install the release cylinder and tube with the four bolts.
20. (M/T) INSTALL STARTER

21. CONNECT FUEL INLET HOSE
Torque: 29 N.m (300 kgf.cm, 22 ft.lbf)

22. CONNECT FUEL RETURN HOSE
23. CONNECT HEATER HOSES
24. CONNECT WIRES AND CONNECTORS

(a) Connect the three connectors to the relay box.
(b) Install the engine relay box.
(c) Two connectors from LH fender apron

(d) Igniter connector
(e) Noise filter connector
(f) Connector from fender apron

(g) Data link connector 1
(h) (w/ A/C) A/C magnet switch connector
(i) Ground strap from RH fender apron
(j) Vacuum sensor connector
(k) (M/T) Back-up light switch connector
(l) (M/T) Speed sensor connector

25. INSTALL WASHER TANK
(a) Connect the connector and vinyl hose to the washer tank.
(b) Install the washer tank with the three bolts.

26. INSTALL COOLANT RESERVOIR HOSE
- Connect the reservoir hose with the bolt.

27. INSTALL RADIATOR
28. CONNECT GROUND STRAP TO BATTERY CARRIER

29. (w/ CRUISE CONTROL SYSTEM) INSTALL CRUISE CONTROL ACTUATOR
(a) Install the actuator and bracket with the three bolts.
(b) Connect the actuator connector.
(c) Install the actuator cover.

30. INSTALL AIR CLEANER ASSEMBLY, RESONATOR AND AIR CLEANER HOSE
(a) Install the air cleaner case with three bolts.
(b) Install the element.
(c) Connect the air cleaner hose to the throttle body.
(d) Install the air cleaner cap together with the resonator and air cleaner hose.
(e) Connect the air intake temperature sensor connector.
(f) Connect the cruise control actuator cable to the clamp on the resonator and cleaner cap.

31. (A/T) CONNECT THROTTLE CABLE, AND ADJUST IT
32. INSTALL ACCELERATOR CABLE, AND ADJUST IT
33. FILL WITH ENGINE COOLANT

Capacity (w/ Heater): 6.3 liters (6.7 US qts. 5.5 Imp. qts)

34. FILL WITH ENGINE OIL

Capacity (M/T):
Drain and refill:
w/ Oil filter change: 4.1 liters (4.3 US qts, 3.6 Imp. qts)
w/o Oil filter change: 3.7 liters (3.9 US qts. 3.3 Imp. qts)
Dry fill: 4.5 liters (4.8 US qts. 4.0 Imp. qts)

Capacity (A/T):
Drain and refill:
w/ Oil filter change: 4.2 liters (4.4 US qts, 3.7 Imp. qts)
w/o Oil filter change: 3.8 liters (4.0 US qts, 3.3 Imp. qts)
Dry fill: 4.6 liters (4.9 US qts, 4.0 Imp. qts)

35. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY
36. START ENGINE AND CHECK FOR LEAKS

37. PREFORM ENGINE ADJUSTMENT
(a) Adjust the generator drive belt.

Drive belt tension:
w/ A/C:
New belt: 175 ± 5 lbf
Used belt: 130 ± 10 lbf
w/o A/C
New belt: 125 ± 25 lbf
Used belt: 95 ± 20 lbf

(b) Adjust the PS drive belt.

Drive belt tension:
New belt: 125 ± 25 lbf
Used belt: 80 ± 20 lbf

(c) Adjust the ignition timing.

Ignition timing: 1O°BTDC @ idle
(w/ Terminals TE1 and E1 connected)

38. INSTALL ENGINE UNDER COVERS
39. INSTALL HOOD
40. PERFORM ROAD TEST
- Check for abnormal noise, chock, slippage, correct shift points and smooth operation.
41. RECHECK ENGINE COOLANT AND ENGINE OIL LEVELS