Engine: Service and Repair

Passenger Compartment (Engine ECU):

REMOVAL
1. REMOVE HOOD
2. REMOVE FRONT FENDER APRON SEALS
3. DRAIN ENGINE COOLANT
4. DRAIN ENGINE OIL
5. DISCONNECT ACCELERATOR CABLE
6. REMOVE AIR CLEANER CAP
a. Disconnect the IAT sensor connector.
b. Disconnect the VSV connector for the EVAP
c. Disconnect the PCV hose from the cylinder head cover.
d. Disconnect the EVAP hose from the throttle body.
e. Disconnect the EVAP hose from the VSV.
f. Disconnect the 2 clamps, and disconnect the air cleaner cap from the air cleaner case.
g. Loosen hose clamp, and disconnect the air cleaner hose from the throttle body.
h. Remove the air cleaner cap and hose assembly.
7. REMOVE AIR CLEANER CASE
a. Remove the air filter.
b. Remove the 3 bolts and air cleaner case.
8. REMOVE BATTERY AND TRAY
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 3 nuts holding the front exhaust pipe to the exhaust manifold.
e. Remove the front exhaust pipe and 2 gaskets.
f. Remove the nut and support bracket.
12. DISCONNECT CONNECTORS, WIRES, CABLES, CLAMPS AND HOSES
a. Disconnect the generator wire.
b. Disconnect the generator connector.
c. Disconnect the wire clamp from the generator.
d. Disconnect the starter cable.
e. Disconnect the starter connector.
f. Disconnect the DLC1 from the bracket.
g. Disconnect the engine wire clamp from the bracket on the RH fender apron.
h. Disconnect the MAP sensor connector.
i. Disconnect the wire clamp from the bracket for the MAP sensor.
j. Disconnect the 2 ground strap connectors from the RH fender apron.
k. Disconnect the 2 ground strap connectors from the LH fender apron.
l. Disconnect the engine wire protector clamp from the battery bracket.
m. Disconnect the engine wire from the clamp on the fuel filter.
n. Disconnect the ground cable from the transaxle.
o. Disconnect the brake booster vacuum hose from the intake manifold.
p. Disconnect the heater hose from the water outlet.
q. Disconnect the heater hose from the water bypass pipe.
r. Disconnect the fuel inlet hose from the fuel filter.
s. Disconnect the MAP sensor vacuum hose from the gas filter on the intake manifold.





13. DISCONNECT ENGINE WIRE FROM CABIN
a. Remove the under cover.
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. DISCONNECT TRANSAXLE CONTROL CABLE(S) FROM TRANSAXLE
16. M/T: REMOVE STARTER
17. M/T: DISCONNECT CLUTCH RELEASE CYLINDER AND TUBE FROM TRANSAXLE





18. DISCONNECT A/C COMPRESSOR FROM ENGINE
a. Disconnect the A/C compressor connector.
b. Remove the drive belt.
c. Remove the 3 bolts, and disconnect the AIC compressor from the engine.
d. Remove the cylinder block insulator.





19. DISCONNECT PS PUMP FROM ENGINE
a. Disconnect the PS oil pressure switch connector.
b. Loosen the 2 bolts, and remove the drive belt.
c. Remove the 2 bolts, and disconnect the PS pump from the engine.
20. REMOVE BOLTS HOLDING TRANSAXLE TO LH ENGINE MOUNTING INSULATOR





a. M/T: Remove the 3 bolts.





b. A/T: Remove the 4 bolts.





21. REMOVE NUTS HOLDING REAR ENGINE MOUNTING BRACKET TO FRONT FRAME
a. Remove the 2 hole plugs.
b. Remove the 3 nuts.





22. REMOVE BOLTS HOLDING FRONT ENGINE MOUNTING INSULATOR TO FRONT FRAME
Remove the 3 bolts.





23. ATTACH ENGINE SLING DEVICE TO ENGINE HANGERS
Attach the engine chain hoist to the engine hangers.

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





24. REMOVE ENGINE MOVING CONTROL ROD
Remove the 3 bolts and control rod.





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

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

b. Place the engine and transaxle assembly onto the stand.
26. REMOVE FRONT ENGINE MOUNTING INSULATOR FROM ENGINE
Remove the 4 bolts and mounting insulator.
27. REMOVE REAR ENGINE MOUNTING INSULATOR FROM ENGINE
Remove the 4 bolts, the mounting insulator.
28. REMOVE NO.2 RH ENGINE MOUNTING BRACKET FROM ENGINE
Remove the 3 bolts and mounting bracket.
29. A/T: DISCONNECT THROTTLE CABLE FROM THROTTLE BODY
30. A/T: REMOVE STARTER
31. DISCONNECT CONNECTORS
a. Disconnect the VSS connector.
b. M/T: Disconnect the back-up light switch connector.
c. A/T: Disconnect the PNP switch connector.
d. A/T: Disconnect the 2 solenoid connectors.





32. REMOVE NO.1 EXHAUST MANIFOLD STAY
Remove the 2 bolts and manifold stay.
33. REMOVE NO.2 EXHAUST MANIFOLD STAY AND LH STIFFENER PLATE
a. TMC Made: Remove the 2 nuts and manifold stay.
b. TMMK Made: Remove the bolt, nut and manifold stay.
c. Remove the 2 bolts and stiffener plate.





34. REMOVE INTAKE MANIFOLD STAY
Remove the 2 bolts and intake manifold stay.
35. REMOVE RH STIFFENER PLATE
Remove the 4 bolts and stiffener plate.





36. REMOVE EXHAUST PIPE BRACKET, OIL PAN INSULATOR AND NO.2 REAR END PLATE
a. Remove the 2 bolts and exhaust pipe bracket.
b. Remove the 2 bolts, oil pan insulator and rear end plate.





37. A/T: REMOVE TORQUE CONVERTER CLUTCH BOLTS
a. Turn the crankshaft pulley bolt to gain access to each bolt.
b. Hold the crankshaft pulley bolt with a wrench, and remove the 6 bolts.





38. REMOVE TRANSAXLE
a. Remove the 4 bolts, ground strap and wire bracket.
b. Remove the transaxle together with the torque converter clutch (A/T) from the engine.
39. M/T: REMOVE CLUTCH COVER AND DISC





40. M/T: REMOVE FLYWHEEL
Remove the 8 bolts and flywheel.
41. A/T: REMOVE DRIVE PLATE
Remove the 8 bolts, front spacer, drive plate and rear spacer.
42. REMOVE NO.1 REAR END PLATE
Remove the bolt and end plate.

INSTALLATION
1. INSTALL NO.1 REAR END PLATE
Install the end plate with the bolt.
Torque: 9.3 Nm (95 kgf-cm, 82 inch lbs.)
2. M/T: INSTALL FLYWHEEL





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





c. Install and uniformly tighten the 8 bolts in several passes, in the sequence shown.
Torque: 88 Nm (900 kgf-cm, 65 ft. lbs.)
3. A/T: INSTALL DRIVE PLATE (See step 2)
Torque: 83 Nm (850 kgf-cm, 61 ft. lbs.)
4. M/T: INSTALL CLUTCH DISC AND COVER
5. A/T: CHECK TORQUE CONVERTER CLUTCH INSTALLATION





6. INSTALL TRANSAXLE TO ENGINE
a. Attach the transaxle to the engine.
b. Install the ground strap, wire bracket and 4 bolts.
Torque:
46 Nm (470 kgf-cm, 34 ft. lbs.) for 14 mm head
64 Nm (650 kgf-cm, 47 ft. lbs.) for 17 mm head





7. A/T: 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: 27 Nm (280 kgf-cm, 20 ft. lbs.)

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





8. INSTALL NO.2 REAR END PLATE, OIL PAN INSULATOR AND EXHAUST PIPE BRACKET
a. Install the oil pan insulator to the rear end plate.
b. Install the rear end plate and exhaust pipe bracket with the 4 bolts.
Torque:
9.3 Nm (95 kgf-cm, 82 inch lbs.) for 10 mm head
19 Nm (195 kgf-cm, 14 ft. lbs.) for 12 mm head





9. INSTALL RH STIFFENER PLATE
Install the stiffener plate with the 4 bolts.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
10. INSTALL INTAKE MANIFOLD STAY
Install the manifold stay with the 2 bolts.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)





11. INSTALL LH STIFFENER PLATE AND NO.2 EXHAUST MANIFOLD STAY
a. TMC Made: Temporarily install the stiffener plate and manifold stay with the 2 bolts and 2 nuts.
b. TMMK Made: Temporarily install the stiffener plate and manifold stay with the 3 bolts and nut.
c. Tighten the 2 bolts holding the stiffener plate to the transaxle.
Torque:
37 Nm (380 kgf-cm, 27 ft. lbs.) for M/T
42 Nm (430 kgf-cm, 31 ft. lbs.) for A/T
d. TMC Made: Tighten the nut holding the manifold stay to the cylinder block.
Torque: 58 Nm (591 kgf-cm, 43 ft. lbs.)
e. TMMK Made: Tighten the bolt holding the manifold stay to the cylinder block.
Torque: 42 Nm (425 kgf-cm, 31 ft. lbs.)
f. Tighten the nut holding the manifold stay to the exhaust manifold.
Torque: 42 Nm (425 kgf-cm, 31 ft. lbs.)
12. INSTALL NO.1 EXHAUST MANIFOLD STAY
Install the manifold stay with the 2 bolts.
Torque: 42 Nm (425 kgf-cm, 31 ft. lbs.)
13. CONNECT CONNECTORS
a. Connect the VSS connector.
b. M/T: Connect the back-up light switch connector.
c. A/T: Connect the PNP switch connector.
d. A/T: Connect the 2 solenoid connectors.
14. A/T: INSTALL STARTER
15. A/T: INSTALL THROTTLE CABLE TO THRO11LE BODY
16. INSTALL NO.2 RH ENGINE MOUNTING BRACKET TO ENGINE
Install the mounting insulator with the 3 bolts.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)
17. INSTALL REAR ENGINE MOUNTING INSULATOR TO ENGINE
Install the mounting insulator with the 4 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
18. INSTALL FRONT ENGINE MOUNTING INSULATOR TO ENGINE
Install the mounting insulator with the 4 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)





19. 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, and lower the engine.
c. Keep the engine level, and attach front and rear mountings to the front frame.





20. INSTALL ENGINE MOVING CONTROL ROD
Install the control rod with the 3 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)





21. INSTALL BOLTS HOLDING FRONT ENGINE MOUNTING INSULATOR TO FRONT FRAME
Install the 3 bolts.
Torque:
TMC made 80 Nm (820 kgf-cm, 59 ft. lbs.)
TMMK made
44 Nm (450 kgf-cm, 32 ft. lbs.) for silver color
66 Nm (670 kgf-cm, 49 ft. lbs.) for green color





22. INSTALL NUTS HOLDING REAR ENGINE MOUNTING INSULATOR TO FRONT FRAME
a. Install the 3 nuts.
Torque: 66 Nm (670 kgf-cm, 49 ft. lbs.)
b. Install the 2 hole plugs.
23. INSTALL BOLTS HOLDING LH ENGINE MOUNTING INSULATOR TO FRONT FRAME





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





b. A/T: Install the 4 bolts.
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
24. REMOVE ENGINE SLING DEVICE
25. CONNECT TRANSAXLE CONTROL CABLE(S) TO TRANSAXLE





26. INSTALL PS PUMP
a. Install the PS pump with the 2 bolts.
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)
b. Install the drive belt.
c. Connect the PS oil pressure switch connector.





27. INSTALL A/C COMPRESSOR
a. Install the cylinder block insulator and A/C compressor with the 3 bolts.
Torque: 25.5 Nm (260 kgf-cm, 19 ft. lbs.)
b. Install the drive belt.
c. Connect the A/C compressor connector.
28. M/T: INSTALL CLUTCH RELEASE CYLINDER AND TUBE TO TRANSAXLE
29. M/T: INSTALL STARTER
30. INSTALL DRIVE SHAFTS





31. 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 under cover.
32. CONNECT CONNECTORS, WIRES, CABLES, CLAMPS AND HOSES
a. Connect the generator wire.
b. Connect the generator connector.
c. Install the wire clamp to the generator.
d. Connect the starter cable.
e. Connect the starter connector.
f. Install the DLC1 to the bracket.
9. Install the engine wire clamp to the bracket on the RH fender apron.
h. Connect the MAP sensor connector.
i. Install the wire clamp to the bracket for the MAP sensor.
j. Connect the VSV connector for the vapor pressure sensor.
k. Connect the 2 ground strap connectors to the RH fender apron.
l. Connect the 2 ground strap connectors to the LH fender apron.
m. Install the engine wire protector clamp to the battery bracket.
n. Install the engine wire to the clamp on the fuel filter.
o. Connect the ground cable to the transaxle.
p. Connect the brake booster vacuum hose to the intake manifold.
q. Connect the heater hose to the water outlet.
r. Connect the heater hose to the water bypass pipe.
s. Connect the fuel inlet hose to the fuel filter with 2 new gaskets and the union bolt.
Torque: 29 Nm (300 kgf-cm, 21 ft. lbs.)
t. Connect the MAP sensor vacuum hose to the gas filter on the intake manifold.





33. INSTALL FRONT EXHAUST PIPE
a. Install the support bracket with the nut.
Torque: 33 Nm (330 kgf-cm, 24 ft. lbs.)
b. Temporarily install 2 new gaskets and the front exhaust pipe with the 2 bolts and 5 nuts.
c. Tighten the 3 nuts holding the exhaust manifold to the front exhaust pipe.
Torque: 62 Nm (630 kgf-cm, 46 ft. lbs.)
d. 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.)
e. Install the bracket with the 2 bolts.
Torque: 33 Nm (330 kgf-cm, 24 ft. lbs.)
f. Install the support stay with the 2 bolts.
Torque: 33 Nm (330 kgf-cm, 24 ft. lbs.)
34. INSTALL RADIATOR
35. INSTALL CRUISE CONTROL ACTUATOR
36. INSTALL BATTERY TRAY AND BATTERY
37. INSTALL AIR CLEANER CASE
Install the air cleaner case with the 3 bolts.
38. INSTALL AIR CLEANER CAP
a. Connect the air cleaner hose to the throttle body.
b. Attach the air cleaner cap to the air cleaner case, and install the 2 clamps.
c. Tighten the air cleaner hose clamp.
d. Connect the PCV hose to the cylinder head cover.
e. Connect the EVAP hose to the throttle body.
f. Connect the EVAP hose to the VSV.
9. Connect the IAT sensor connector.
h. Connect the VSV connector for the EVAP.
39. CONNECT ACCELERATOR CABLE
40. INSTALL ENGINE FENDER APRON SEALS
41. INSTALL HOOD
42. FILL ENGINE WITH OIL
43. FILL WITH ENGINE COOLANT
44. START ENGINE AND CHECK FOR LEAKS
45. RECHECK ENGINE COOLANT AND OIL LEVELS