Engine: Service and Repair

REMOVAL OF ENGINE
1. REMOVE BATTERY
2. DRAIN ENGINE COOLANT
3. REMOVE HOOD

4. REMOVE IGNITER AND BRACKET ASSEMBLY
(a) Disconnect the igniter connector.
(b) Disconnect the ground strap from the bracket.
(c) Remove the two bolts, the igniter and bracket assembly.

5. REMOVE RADIATOR
6. REMOVE RADIATOR RESERVOIR TANK
7. (A/T) DISCONNECT THROTTLE CABLE FROM THROTTLE BODY
8. DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY

9. (w/ CRUISE CONTROL SYSTEM) REMOVE CRUISE CONTROL ACTUATOR
(a) Disconnect the actuator vacuum hose.
(b) Disconnect the actuator connector.
(c) Remove the bolts, actuator and bracket.

10. REMOVE AIR CLEANER ASSEMBLY
(a) Disconnect the air flow meter connector.
(b) Disconnect the four air cleaner cap clips.
(c) Disconnect the air cleaner hose, and air flow meter assembly.
(d) Remove the air cleaner element.
(e) Remove the three bolts and air cleaner case.

11. (M/T) REMOVE CLUTCH RELEASE CYLINDER AND TUBE BRACKET WITHOUT DISCONNECTING TUBE
12. DISCONNECT SPEEDOMETER CABLE
13. DISCONNECT TRANSAXLE CONTROL CABLES

14. (w/ A/C) REMOVE A/C COMPRESSOR WITHOUT DISCONNECTING HOSES
(a) Disconnect the two connectors.
(b) Remove the four compressor bolts.

HINT: Put aside the compressor, and suspend it to the radiator support with a string.

15. DISCONNECT HOSES
(a) Two heater water by-pass hoses
(b) Two fuel hoses

NOTICE: Catch leaking fuel in a container.

(c) Brake booster vacuum hose
(d) A/C control valve vacuum hoses
(e) Charcoal canister vacuum hose

16. DISCONNECT WIRES AND CONNECTORS
(a) Check connector
(b) Ground straps from LH fender apron
(c) Connectors from relay box
(d) Engine room wire connector

17. RAISE VEHICLE

NOTICE: Be sure the vehicle is securely supported.

18. REMOVE ENGINE UNDER COVERS
19. DRAIN ENGINE OIL

20. REMOVE SUSPENSION LOWER CROSSMEMBER
- Remove the four bolts, two nuts and crossmember.

21. REMOVE DRIVE SHAFTS
22. (4WD) REMOVE PROPELLER SHAFT
23. (4W0) REMOVE DEFLECTOR FROM TRANSFER EXTENSION HOUSING
24. REMOVE PS PUMP WITHOUT DISCONNECTING PS HOSES

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

25. REMOVE FRONT EXHAUST PIPE

(a) Loosen the bolt, and disconnect the clamp from the bracket.
(b) Remove the two bolts and nuts, and disconnect the front pipe from the center pipe. Remove the gasket.

26. REMOVE ENGINE MOUNTING CENTER MEMBER
(2WD) Remove the eight bolts, two nuts and center member.
(4WD) Remove the eight bolts, two nuts and center member.

27. REMOVE ENGINE FRONT MOUNTING INSULATOR AND BRACKET
28. (2WD) REMOVE ENGINE CENTER MOUNTING INSULATOR AND BRACKET ASSEMBLY
29. REMOVE ENGINE REAR MOUNTING INSULATOR AND BRACKET
30. LOWER VEHICLE
31. DISCONNECT ENGINE WIRE
(a) Remove the glove compartment box.
(b) Disconnect the following connectors:
(1) Three TCCS ECU connectors
(2) Circuit opening relay connector
(3) Cowl wire connector
(4) Instrument panel wire connector
(c) Pull out the engine wire from the cowl panel.

32. REMOVE P/S OIL RESERVOIR TANK WITHOUT DISCONNECTING HOSES
- Remove the two bolts.

33. REMOVE RH MOUNTING STAY

(2WD) Remove the three bolts and mounting stay.

(4WD) Remove the bait, nut, ground strap and mounting stay.

34. (A/T) REMOVE LH MOUNTING STAY

(2WD) Remove the bolt, nut and mounting stay.

(4WD) Remove the two nuts and mounting stay.

35. REMOVE ENGINE AND TRANSAXLE ASSEMBLY FROM VEHICLE
(a) Attach the engine hoist chain to the engine hangers.

(b) (2WD) Remove the bolt, four nuts and RH mounting insulator.

(d) Remove the through bolt, three bolts (2WD, M/T), four bolts (others) and LH mounting insulator.
(e) Remove the three bolts and LH mounting bracket.

(f) Lift the engine out of the vehicle slowly and carefully.

NOTICE: Be careful not to hit the PS gear housing or neutral start switch.

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

36. SEPARATE ENGINE AND TRANSAXLE

INSTALLATION OF ENGINE
1. ASSEMBLE ENGINE AND TRANSAXLE
2. INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN VEHICLE
(a) Attach the engine hoist chain 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 neutral Start switch.

(c) Keep the engine level, and align RH and LH mounting with the body bracket.
(d) (2WD) Attach the RH mounting insulator to the mounting bracket and body, and temporarily install the bolt and nut.

(e) (2WD) Temporarily install the mounting stay bolt (A).

(f) (4WD) Attach the RH mounting insulator to the mounting bracket and body, and temporarily install the through bolt and two nuts.
(g) Install the LH mounting bracket to the transaxle case with the three bolts. Torque the bolts.
Torque: 530 kg.cm. (38 ft.lb., 52 N.m)

(h) Attach the LH mounting insulator to the mounting bracket and body with the through bolt and three bolts (2WD M/T) or four bolts (others), and install and torque the bolts.
Torque:
Bolt: 530 kg.cm. (38 ft.lb., 52 N.m)
Through bolt: 890 kg.cm. (64 ft.lb., 87 N.m)

(i) (2WD) Torque the bolt and four nuts of the RH mounting insulator. Do not torque the bolt (A) yet.
Torque:
Nut:
To bracket: 530 kg.cm. (38 ft.lb., 52 N.m)
To body: 900 kg.cm. (65 ft.lb., 88 N.m)
Bolt: 650 kg.cm. (47 ft.lb., 64 N.m)

(j) (4WD) Torque the through bolt and two nuts of the RH mounting insulator.
Torque:
Nut: 530 kg.cm. (38 ft.lb., 52 N.m)
Through bolt: 890 kg.cm. (64 ft.lb., 87 N.m)

(k) Remove the engine hoist chain from the engine.

3. INSTALL ENGINE RH MOUNTING STAY

(2WD) Install the mounting stay with the three bolts. Torque the bolts.
Torque: 740 kg.cm. (54 ft.lb., 73 N.m)

(4WD) Install the mounting stay with the bolt and nut. Torque the bolt and nut.
Torque: 740 kg.cm. (54 ft.lb., 73 N.m)

4. (A/T) INSTALL ENGINE LH MOUNTING STAY

(2WD) Install the mounting stay with the bolt and nut. Torque the bolt and nut.
Torque: 210 kg.cm. (15 ft.lb., 21 N.m)

(4WD) Install the mounting stay with the two nuts.
Torque: 210 kg.cm. (15 ft.lb., 21 N.m)

5. INSTALL PS OIL RESERVOIR TANK
- Install the two bolts.

6. CONNECT ENGINE WIRE
(a) Push in the engine wire through the cowl panel.
(b) Connect the following connectors.
(1) Three TCCS ECU connectors
(2) Circuit opening relay connector
(3) Cowl wire connector
(4) Instrument panel wire connect9r
(c) Install the glove compartment box.

7. RAISE VEHICLE

NOTICE: Be sure the vehicle is securely supported.

8. INSTALL ENGINE FRONT MOUNTING BRACKET AND INSULATOR
(a) Install the mounting bracket with the two bolts. Torque the bolts.
Torque: 790 kg.cm. (57 ft.lb., 77 N.m)

(b) Temporarily install the mounting insulator with the through bolt and nut.

9. (2WD) INSTALL ENGINE CENTER MOUNTING BRACKET AND INSULATOR ASSEMBLY
- Install the mounting bracket and insulator assembly with the two bolts. Torque the bolts.
Torque: 490 kg.cm. (35 ft.lb., 48 N.m)

10. INSTALL ENGINE REAR MOUNTING BRACKET AND INSULATOR

(M/T)
(a) Install the mounting bracket with the three bolts. Torque the bolts.
Torque: 790 kg.cm. (57 ft.lb., 77 N.m)

(b) Temporarily install the mounting insulator with the through bolt and nut.

(2WD A/T)
(a) Install the mounting bracket with the two bolts. Torque the bolts.
Torque: 790 kg.cm. (57 ft.lb., 77 N.m)

(b) Temporarily install the mounting insulator with the through bolt and nut (damper).

(4WD)
(a) Install the mounting bracket with the two bolts. Torque the bolts.
Torque: 790 kg.cm. (57 ft.lb., 77 N.m)

(b) Temporarily install the mounting insulator with the through bolt.

11. INSTALL ENGINE MOUNTING CENTER MEMBER
(a) Install the engine mounting center member with the four bolts. Torque the bolts.
Torque: 400 kg.cm. (29 ft.lb., 39 N.m)

(b) Install and torque the four bolts and two nuts (2WD) holding the mounting insulators to the center member.
Torque:
Nut: 490 kg.cm. (35 ft.lb., 48 N.m)
Bolt: 740 kg.cm. (54 ft.lb., 73 N.m)

(c) Torque the mounting insulator through bolts (front and rear.)
Torque: 890 kg.cm. (64 ft.lb., 87 N.m)

12. INSTALL FRONT EXHAUST PIPE
(a) Place two new gaskets on the front and rear of the front pipe.
(b) Install the front pipe with the two bolts and five new nuts. Torque the nuts.
Torque:
To manifold: 630 kg.cm. (46 ft.lb.. 62 N.m)
To converter: 440 kg.cm. (32 ft.lb., 43 N.m)

(c) Install the clamp with the bolt.

13. INSTALL P/S PUMP
14. (4WD) INSTALL DEFLECTOR TO TRANSFER EXTENSION HOUSING
15. (4WD) INSTALL PROPELLER SHAFT
16. INSTALL DRIVE SHAFTS

17. INSTALL SUSPENSION LOWER CROSSMEMBER
(a) Install the crossmember with the two bolts and two nuts. Torque the bolts and nuts.

CAUTION: The tightening torque differs depending on the bolt and nut used.
First check which type of bolt and which type of nut is used, then apply the specified tightening torque.

Bolt tightening torque:
Head mark 10: 2,110 kg.cm. (153 ft.lb., 207 N.m)
Head mark 11: 1,550kg.cm. (112 ft.lb., 152 N.m)

Nut tightening torque:
Nut height 13 mm: (0.51 in.) 2,110 kg.cm. (153 ft.lb., 207 N.m)
Nut height 17.3 mm: (0.681 in.) 1,550 kg.cm. (112 ft.lb., 152 N.m)

(b) Install the two bolts holding the crossmember to the center member. Torque the bolts.
Torque: 400 kg.cm. (29 ft.lb., 39 N.m)

18. INSTALL ENGINE UNDER COVERS
19. CONNECT WIRES AND CONNECTORS
(a) Check connector
(b) Ground straps from LH fender apron
(c) Connectors from relay box
(d) Engine room wire connector -

20. CONNECT HOSES
(a) Two heater water by-pass hoses
(b) Two fuel hoses
(c) Brake booster vacuum hoses'
(d) A/C idle-up vacuum hoses
(e) Charcoal canister vacuum hose

21. (w/ A/C) INSTALL A/C COMPRESSOR
(a) Install the compressor with the four bolts.
(b) Connect the two connectors.

22. CONNECT TRANSAXLE CONTROL CABLE
23. CONNECT SPEEDOMETER CABLE

24. (M/T) INSTALL CLUTCH RELEASE CYLINDER AND TUBE CLAMP

25. INSTALL AIR CLEANER ASSEMBLY
(a) Install the air cleaner case with the three bolts.
(b) Install the air cleaner element.
(c) Connect the air cleaner hose, and install the air cleaner cap and air flow meter assembly with the four clips.
(d) Connect the air flow meter connector.

26. (w/CRUISE CONTROL SYSTEM) INSTALL CRUISE CONTROL ACTUATOR
(a) Install the actuator and bracket with the bolts.
(b) Connect the actuator connector.
(c) Connect the actuator vacuum hose.

27. (A/T) INSTALL THROTTLE CABLE, AND ADJUST IT
28. INSTALL ACCELERATOR CABLE, AND ADJUST IT
29. INSTALL RADIATOR RESERVOIR TANK
30. INSTALL RADIATOR

31. INSTALL IGNITER AND BRACKET ASSEMBLY
(a) Install the igniter and bracket assembly with the two bolts.
(b) Connect the igniter connector.
(c) Connect the ground strap.

32. INSTALL BATTERY
33. FILL WITH ENGINE COOLANT

Capacity (w/ Heater):
M/T: 6.4 liters (6.8 US qts, 5.6 Imp. qts)
A/T:
2WD: 6.3 liters (6.7 US qts, 5.5 Imp. qts)
4WD: 6.8 liters (7.2 US qts, 6.0 Imp. qts)

34. FILL WITH ENGINE OIL

Capacity:
Drain and refill:
w/ Oil filter change: 3.9 liters (4.1 US qts, 3.4 Imp. qts)
w/o Oil filter change: 3.7 liters (3.9 US qts, 3.3 Imp. qts)
Dry fill: 4.3 liters (4.5 US qts, 3.8 Imp. qts)

35. START ENGINE AND CHECK FOR LEAKS
36. PERFORM ENGINE ADJUSTMENT
(a) Adjust the alternator drive belt.

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

(b) Adjust the PS drive belt.

Drive belt tension:
New belt: 125 ± 25 lbs.
Used belt: 80 ± 20 lbs.

(c) Adjust the ignition timing.

Ignition timing: 10° BTDC @ idle
(w/Terminals TE1 and E1 connected)

(d) Adjust the valve clearance.

Valve clearance:
Intake: 0.19 - 0.29 mm (0.007 - 0.011 in.)
Exhaust: 0.28 - 0.38 mm (0.011 - 0.015 in.)

37. INSTALL HOOD
38. PERFORM ROAD TEST
- Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
39. RECHECK ENGINE COOLANT AND ENGINE OIL LEVELS