Engine: Service and Repair

Engine Removal

NOTE:
^ Use fender covers to avoid damaging painted surfaces.
^ To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
^ Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring or hoses, or interfere with other parts.





1. Remove the hood support rod from the driver's side of the car, then use it as shown to fix the hood in a vertical position.
2. Make sure you have the anti-theft code for the radio, then write down the customer's radio station presets.
3. Disconnect the negative cable from the battery first, then disconnect the positive cable.
4. Remove the battery.
5. Remove the transmission.





6. Disconnect the Engine Control Module (ECM) connectors (A) from the ECM.
7. Disconnect the dashboard wire harness A connector (B).





8. Remove the vacuum tank.





9. Remove the throttle cable (A) by loosening the locknut (B), then slipping the cable end out of the accelerator linkage. Take care not to bend the cable when removing it. Always replace any kinked cable with a new one.





10. Remove the four bolts (A) securing the Electrical Power Steering (EPS) control unit (B).





11. Remove the battery cable (A) from the main under-hood fuse/relay box, then remove the harness clamps (B).





12. Remove the battery cable (A) from the auxiliary under-hood fuse/relay box, and remove the ground cable (B) and harness clamps (C).
13. Remove the grommet (D), then pull out the ECM connectors.
14. Remove the radiator cap.
15. Raise the vehicle on the hoist.
16. Remove the front tires/wheels.
17. Loose the drain plug in the radiator, and drain the engine coolant.
18. Drain the engine oil. Reinstall the drain bolt using a new washer.





19. Remove the engine stop bracket cushion (A), then remove the engine stop bracket (B).
20. Lower the vehicle on the hoist.





21. Remove the heater hoses (A) and lower radiator hose (B).





22. Remove the upper radiator hose.
23. Relieve fuel pressure.
24. Remove the fuel feed hose (A), fuel return hose (B) and brake booster vacuum hose (C).





2004-2005 models





25. Remove the Evaporative Emission (EVAP) canister hose.





26. Remove the two bolts securing the engine stop bracket.





27. Attach the chain hoist to the engine as shown.
Take care not to damage the VTEC solenoid valve.





28. Remove the support nut from the left side engine mount bracket.





29. Remove the support nut (A) and four mounting bolts (B), then remove the right side engine mount bracket (C).
30. Check that the engine is completely free of vacuum hoses, fuel and coolant hoses, and electrical wiring.
31. Slowly raise the engine about 150 mm (6 inch). Check once again that all hoses and wires are disconnected from the engine.
32. Raise the engine all the way, and remove it from the vehicle.

Engine Installation





1. Install the accessory brackets, and tighten their bolts to the specified torques.
2. Install the engine into position in the vehicle.

NOTICE: Reinstall the mounting bolts/support nuts in the sequence given. Failure to follow this sequence may cause excessive noise and vibration, and reduce bushing life.





3. Install the right side engine mount bracket, then tighten the bolts and nut in the numbered sequence shown.





4. Tighten the support nut on the left side engine mount bracket.





5. Tighten the two bolts securing the engine stop bracket.





6. Install the Evaporative Emission (EVAP) canister hose.
7. Install the brake booster vacuum hose (A), fuel return hose (B) and fuel feed hose (C), using new washers (D).





2004-2005 models





8. Install the upper radiator hose.





9. Install the heater hoses (A) and lower radiator hose (B).
10. Raise the vehicle on the hoist.





11. Install the engine stop bracket (A), then install the engine stop bracket cushion (B).
12. Install the front tires/wheels.
13. Lower the vehicle on the hoist.





14. Push the Engine Control Module (ECM) connectors through the bulkhead, then install the grommet (A).
15. Install the battery cable (B) on the auxiliary underhood fuse/relay box. Install the ground cable (C) and harness clamps (D).





16. Connect the ECM connectors (A) and dashboard wire harness A connector (B).





17. Install the harness clamps (A), then install the battery cable (B) on the main under-hood fuse/relay box.





18. Install the Electrical Power Steering (EPS) control unit.





19. Install the vacuum tank.
20. Install the throttle cable, then adjust the cable.
21. Install the transmission.
22. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion.
23. Inspect for fuel leaks. Turn the ignition switch ON (II) (do not operate the starter) so that the fuel pump runs for about 2 seconds and pressurizes the fuel line. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
24. Refill the engine with engine oil.
25. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
26. Check that the transmission shifts into gear smoothly.
27. Do the ECM idle learn procedure.
28. Inspect the idle speed.
29. Inspect the ignition timing.
30. Enter the anti-theft code for the radio, then enter the customer's radio station presets.
31. Set the clock.