Engine: Service and Repair

REMOVAL
1. REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT AND OIL
3. DRAIN TRANSMISSION OIL
4. REMOVE HOOD
5. REMOVE RADIATOR ASSEMBLY
6. DISCONNECT HEATER HOSES
7. REMOVE FAN WITH FLUID COUPLING AND FAN PULLEYS
8. REMOVE AIR CLEANER ASSEMBLY
9. DISCONNECT CABLES
a. Disconnect the accelerator cable.
b. A/T: Disconnect the throttle cable.
c. w/ Cruise control: Disconnect the cruise control actuator cable.
10. DISCONNECT HOSES





a. Disconnect the brake booster vacuum hose.
b. Disconnect the EVAP hose.
c. Disconnect the vacuum hose.





d. Disconnect the fuel return hose.
e. Disconnect the fuel inlet hose.





11. DISCONNECT STARTER WIRE AND CONNECTORS
a. Remove the bolt and disconnect the ground strap.
b. Remove the 2 nuts, disconnect the positive (+) terminal cable from the battery.
c. Disconnect the 2 starter wire clamps and 2 connectors.
d. Remove the nut and disconnect the starter wire from the relay block No.2.
12. DISCONNECT GENERATOR WIRE





13. DISCONNECT ENGINE WIRE FROM CABIN
a. Remove the glove compartment door.
b. Remove the lower finish No.2 panel.
c. Remove the heater to register duct.
d. Remove the 2 bolts and ECM.
e. Disconnect the 3 ECM connectors.
f. Disconnect the 2 cassette connectors.
g. Disconnect the igniter connector.
h. Disconnect the ground strap.
i. Disconnect the engine wire from the engine wire bracket and remove the bolt, 2 nuts and bracket.
j. Pull out the engine wire from the cabin.
14. 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 gasket.
15. REMOVE PROPELLER SHAFT
16. DISCONNECT SPEEDOMETER CABLE

NOTICE: Do not lose the felt protector and washers.

17. REMOVE FRONT EXHAUST PIPE
18. M/T: REMOVE CLUTCH RELEASE CYLINDER
Remove the 2 bolts, and disconnect the clutch clutch release cylinder.
19. PLACE JACK UNDER TRANSMISSION





20. REMOVE REAR CROSSMEMBER
a. Remove the 4 bolts and mounting bracket from the crossmember.
b. Remove the 4 bolts, nuts and crossmember.
21. REMOVE ENGINE WITH TRANSMISSION
a. w/ A/C: Remove the bolt and disconnect the A/C compressor wire clamp.





b. Install an engine hanger No.2 in the correct direction.
Part No.:
Engine hanger No.2 12282-62050
Bolt 91 512 - 61020
Torque: 40 Nm (400 kgf-cm, 30 ft. lbs.)





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





d. Remove the 4 bolts and nuts holding the engine front mounting insulators to the frame.





e. Lift the engine with transmission out of the vehicle slowly and carefully.

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

f. Place the engine and transmission assembly onto the stand.
22. 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 engine chain hoist from the engine.
g. Remove the 2 bolts and engine hanger No.2.
h. w/ A/C: Connect the A/C compressor wire with the bolt.





3. INSTALL ENGINE REAR CROSSMEMBER
a. Raise the transmission slightly by raising the engine with a jack and a wooden block under the transmission.
b. Install the 4 bolts, nuts and crossmember.
Torque: 58 Nm (590 kgf-cm, 43 ft. lbs.)
c. Lower the transmission and rest it on the extension housing.
d. Install the crossmember mounting bracket with the 4 bolts.
Torque: 18 Nm (185 kgf-cm, 13 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. M/T: INSTALL CLUTCH RELEASE CYLINDER
Install the clutch release cylinder with the 2 bolts.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
6. INSTALL FRONT EXHAUST PIPE
7. CONNECT SPEEDOMETER CABLE
8. INSTALL PROPELLER SHAFT
9. M/T: INSTALL SHIFT LEVER ASSEMBLY
a. Install a new gasket and the shift lever assembly with the 6 bolts.
b. Install the shift lever boot with the 4 screws.
c. Install the shift lever knob.





10. CONNECT ENGINE WIRE TO CABIN
a. Push in the engine wire through the cowl panel.
b. Install the bolt and 2 nuts.
c. Connect the ground strap.
d. Connect the igniter connector.
e. Connect the 3 ECM connectors.
f. Connect the 2 cassette connectors.
g. Install the ECM with the 2 bolts.
h. Install the heater to register duct.
i. Install the lower finish No.2 panel.
j. Install the glove compartment door.
11. CONNECT GENERATOR WIRE





12. CONNECT STARTER WIRE AND CONNECTOR
a. Connect the 2 starter wire clamps and connector.
b. Install the 2 nuts and connect the positive (+) terminal cable to the battery.
c. Connect the ground strap with the bolt.
d. Connect the starter wire to the relay block No.2 with the nut.
13. 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. Connect the vacuum hose.
f. Connect the heater hoses.
14. CONNECT CABLES
a. Connect the accelerator cable.
b. A/T: Connect the throttle cable.
c. w/Cruise control: Connect the cruise control actuator cable.
15. INSTALL FAN WITH FLUID COUPLING AND FAN PULLEYS
16. INSTALL RADIATOR ASSEMBLY
17. INSTALL AIR CLEANER ASSEMBLY
18. FILL WITH ENGINE OIL AND COOLANT
19. FILL TRANSMISSION OIL
20. START ENGINE AND CHECK FOR LEAKS
21. INSTALL ENGINE UNDER COVER
22. INSTALL HOOD
23. ROAD TEST VEHICLE
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
24. RECHECK ENGINE COOLANT AND ENGINE OIL LEVELS