Engine: Service and Repair

REMOVAL
1. REMOVE BATTERY AND TRAY
2. REMOVE HOOD
3. REMOVE ENGINE UNDER COVERS
4. DRAIN ENGINE COOLANT
5. DRAIN ENGINE OIL
6. DRAIN TRANSAXLE OIL
7. REMOVE BUMPER COVER AND HEAD LIGHT





8. REMOVE AIR CLEANER CAP
a. Disconnect the MAF meter connector.
b. Disconnect the VSV for EVAP.
c. Disconnect the 2 hoses.
d. Disconnect the 3 clamps, and disconnect the air cleaner cap from the air cleaner case.
e. Loosen the hose clamp, and disconnect the air cleaner hose from the throttle body.





9. REMOVE AIR CLEANER CASE
a. Remove the air filter.
b. Disconnect the hose from the VSV for Canister Closed VALVE (CVC).
c. Disconnect the hose from the intake air control valve.
d. Remove the 2 bolts, and disconnect the air cleaner case.
e. Disconnect the 2 hoses from the air cleaner case.
10. REMOVE ECM BOX





a. Remove the 2 bolts and ECM cover.
b. Disconnect the 4 connectors from the ECM.
c. Disconnect the 2 connectors from the ECM box.
d. Remove the ECM from the ECM box.
e. Disconnect the clamp from the ECM box.
f. Disconnect the 2 engine wires from the ECM box.
g. Remove the 3 bolts and ECM box.





h. Remove the 2 nuts, bolt and ECM box stay.
11. DISCONNECT ENGINE WIRE FROM ENGINE COMPARTMENT RELAY BOX





a. Remove the relay box upper cover.
b. Disconnect the 3 connectors.
c. Disconnect the 7 claws and J/B from the relay box.





d. Disconnect the 3 connectors.
e. Disconnect the engine wire from the relay box.





12. w/ Cruise Control System: DISCONNECT CRUISE CONTROL ACTUATOR
a. Disconnect the actuator connector.
b. Remove the 3 bolts and disconnect the actuator from the body.
13. REMOVE RADIATOR ASSEMBLY
14. REMOVE DRIVE BELT AND GENERATOR





15. w/ A/C: DISCONNECT A/C COMPRESSOR
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.

16. DISCONNECT TUBE AND HOSE
a. Disconnect the fuel tube from the fuel pipe on vehicle side.
b. Disconnect the 2 heater hoses from the engine side.
c. Disconnect the brake booster vacuum hose.





17. M/T: DISCONNECT CLUTCH RELEASE CYLINDER
a. Remove the 3 bolts, and disconnect the brackets from the transaxle.
b. Remove the 2 bolts, and disconnect the release cylinder from the transaxle.
18. DISCONNECT TRANSAXLE CONTROL CABLE (S)
19. DISCONNECT 2 GROUND CABLES
20. REMOVE DRIVE SHAFT
21. REMOVE EXHAUST PIPE





a. Disconnect the 2 heated oxygen sensor.





b. Remove the 4 bolts and springs.
c. Disconnect the 2 O-rings, and remove the exhaust pipe and 2 gaskets.





22. 1ZZ-FE: REMOVE EXHAUST MANIFOLD
a. Remove the 6 bolts and upper heat insulator.
b. Remove the 3 bolts and exhaust manifold stay.
c. Remove the 5 nuts, exhaust manifold and gasket.





23. 2ZZ-GE: REMOVE EXHAUST MANIFOLD
a. Remove the 5 bolts and upper heat insulator.
b. Remove the 4 bolts and exhaust manifold stay.
c. Remove the 2 nuts, 3 bolts, exhaust manifold and gasket.
24. DISCONNECT PS PUMP
a. Disconnect the PS oil pressure switch connector.
b. Remove the 2 nuts and through bolts, and disconnect the PS pump from the engine.

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

25. REMOVE STABILIZER BAR BRACKET
26. DISCONNECT PS GEAR
Remove the 4 bolts, and disconnect the PS gear from the suspension member.

HINT: Suspend the PS gear securely.





27. REMOVE SUSPENSION MEMBER
Remove the 9 bolts, 3 nuts and suspension member.





28. ATTACH ENGINE SLIDING DEVICE TO ENGINE HANGER
a. Remove the 4 bolts and No. 2 cylinder head cover.
b. Disconnect the PCV hoses from the cylinder head cover.
c. Install the 2 engine hangers in the correct direction.
Engine hanger part No.:
1ZZ-FE
Front: 12281-22021
Rear: 12281-15040 or 12281-15050
Bolt: 91512-B1016
2ZZ-GE
Front: 12281-88600
Rear: 12282-88600
Bolt: 91512-61020
Torque: 38 Nm (388 kgf-cm, 28 ft. lbs.)
d. Attach the engine sling device to the engine hangers.

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





29. REMOVE REAR ENGINE MOUNTING
a. Remove the through bolt and rear engine mounting insulator.
b. Remove the 3 bolts and rear engine mounting bracket.
30. REMOVE ENGINE AND TRANSAXLE ASSEMBLY





a. Remove the LH engine mounting through bolt and nut.





b. 1ZZ-FE:
Remove the 4 bolts, 2 nuts and RH engine mounting insulator.
c. 2ZZ-E: Remove the 5 bolts, 2 nuts and RH engine mounting insulator.





d. Lower the engine out of vehicle slowly and carefully, and raise the vehicle.

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

e. Place the engine and transaxle assembly onto the stand.
31. SEPARATE ENGINE AND TRANSAXLE

INSTALLATION
1. ASSEMBLY ENGINE AND TRANSAXLE
2. INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN VEHICLE





a. Attach the engine sling device to the engine hangers.
b. Slowly lower the vehicle, and raise the engine into the engine compartment.
c. Keep the engine level, and align RH and LH mountings with the body bracket.





d. 1ZZ-FE: Install the RH engine mounting insulator with the 4 bolts and 2 nuts.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)
e. 2ZZ-GE: Install the RH engine mounting insulator with the 5 bolts and 2 nuts.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)





f. Install the LH engine mounting through bolt and nut.
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)
3. REMOVE ENGINE SLING DEVICE





4. INSTALL REAR ENGINE MOUNTING
a. Install the rear engine mounting bracket with the 3 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
b. Temporarily install the rear engine mounting insulator with the through bolt.





5. INSTALL SUSPENSION MEMBER
a. Install the suspension member with the 9 bolts and 3 nuts.
Torque:
A 52 Nm (530 kgf-cm, 32 ft. lbs.)
B 52 Nm (530 kgf-cm, 32 ft. lbs.)
C 157 Nm (1,600 kgf-cm, 116 ft. lbs.)
D 157 Nm (1,600 kgf-cm, 116 ft. lbs.)
E 39 Nm (400 kgf-cm, 29 ft. lbs.)
Nut 52 Nm (530 kgf-cm, 32 ft. lbs.)
b. Tighten the rear engine mounting through bolt.
Torque: 87 Nm (887 kgf-cm, 64 ft. lbs.)
6. CONNECT PS GEAR
Install the PS gear with the 4 bolts.
Torque: 45 Nm (460 kgf-cm, 33 ft. lbs.)
7. INSTALL STABILIZER BAR BRACKET
8. CONNECT PS PUMP
a. Install the PS pump with the 2 through bolts and nuts.
Torque: 36 Nm (370 kgf-cm, 27 ft. lbs.)
b. Connect the PS oil pressure switch connector.





9. 1ZZ-FE:
INSTALL EXHAUST MANIFOLD
a. Install the gasket and exhaust manifold with the 5 nuts.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)
b. Install the exhaust manifold stay with the 3 bolts.
Torque: 49 Nm (500 kgf-cm, 37 ft. lbs.)
c. Install the upper heat insulator with the 6 bolts.
Torque: 12 Nm (123 kgf-cm, 9 ft. lbs.)





10. 2ZZ-GE:
INSTALL EXHAUST MANIFOLD
a. Install the gasket and exhaust manifold with the 2 nuts and 3 bolts.
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)
b. Install the exhaust manifold stay with the 4 bolts.
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)
c. Install the upper heat insulator with the 5 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
11. INSTALL EXHAUST PIPE





a. Install the 2 gaskets and exhaust pipe.
b. Connect the 2 O-rings.
c. Install the 4 springs and bolts.
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)





d. Connect the 2 heated oxygen sensor.
12. INSTALL DRIVE SHAFT
13. CONNECT 2 GROUND CABLES
14. CONNECT TRANSAXLE CONTROL CABLE (S)





15. M/T:
CONNECT CLUTCH RELEASE CYLINDER
a. Install the release cylinder with the 2 bolts.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
b. Install the brackets with the 3 bolts.
Torque:
Bolt A 12 Nm (120 kgf-cm, 9 ft. lbs.)
Bolt B 4.9 Nm (50 kgf-cm, 43 inch lbs.)
16. CONNECT TUBE AND HOSE
a. Connect the brake booster vacuum hose.
b. Connect the 2 heater hoses to the engine side.
c. Connect the fuel tube to the fuel pipe on vehicle side.





17. W/ A/C
INSTALL A/C COMPRESSOR
a. Install the A/C compressor with the 3 bolts.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
b. Connect the A/C compressor connector.
18. INSTALL GENERATOR AND DRIVE BELT
19. INSTALL RADIATOR ASSEMBLY





20. w/ Cruise Control System: INSTALL CRUISE CONTROL ACTUATOR
a. Install the actuator with the 3 bolts.
b. Connect the actuator connector.
21. CONNECT ENGINE WIRE TO ENGINE COMPARTMENT RELAY BOX





a. Install the engine wire to the relay box.
b. Connect the 3 connectors.





c. Connect the J/B to the relay box.
d. Connect the 3 connectors.
e. Install the relay box upper cover.
22. INSTALL ECM BOX





a. Install the ECM box stay with the 2 nuts and bolt.
Torque:
Nut 12 Nm (120 kgf-cm, 9 ft. lbs.)
Bolt 18 Nm (185 kgf-cm, 13 ft. lbs.)





b. Instal the ECM box with the 3 bolts.
Torque: 6.9 Nm (70 kgf-cm, 61 inch lbs.)
c. Connect the 2 engine wire to the ECM box.
d. Connect the clamp to the ECM box.
e. Install the ECM to the ECM box.
f. Connect the 2 connectors to the ECM box.
g. Connect the 4 connectors to the ECM
h. Install the ECM cover with the 2 bolts.
Torque: 6.9 Nm (70 kgf-cm, 61 inch lbs.)





23. INSTALL AIR CLEANER CASE
a. Connect the 2 hoses to the air cleaner case.
b. Install the air cleaner case with the 2 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
c. Connect the hose to the intake air control valve.
d. Connect the hose to the VSV for Canister Closed Valve (CVC).
e. Install the air filter.





24. INSTALL AIR CLEANER CAP
a. Install the air cleaner hose to the throttle body with the hose clamp.
b. Connect the air cleaner cap to the air cleaner case with the 3 clamps.
c. Connect the 2 hoses.
d. Connect the VSV for EVAP.
e. Connect the MAF meter connector.
25. INSTALL HEADLIGHT AND BUMPER COVER
26. INSTALL BATTERY AND TRAY
27. FILL WITH TRANSAXLE OIL
28. FILL WITH ENGINE OIL
29. FILL WITH ENGINE COOLANT
30. START ENGINE AND CHECK FOR LEADS
31. PERFORM ENGINE ADJUSTMENT
32. CHECK FRONT WHEEL ALIGNMENT
33. INSTALL ENGINE UNDER COVERS
34. INSTALL ENGINE HOOD
35. ROAD TEST VEHICLE
Check for abnormal noises, shock slippage, correct shift points and smooth operation.
36. RECHECK ENGINE COOLANT AND OIL LEVELS