Engine: Service and Repair

REMOVAL OF ENGINE
1. REMOVE BATTERY
- Disconnect the ground strap.
2. DRAIN ENGINE COOLANT
3. REMOVE HOOD
4. REMOVE ENGINE UNDER COVERS
5. DRAIN ENGINE COOLANT
6. DRAIN ENGINE OIL

7. REMOVE IGNITION COIL, IGNITER AND BRACKET ASSEMBLY
(a) Disconnect the following cord and connectors:
(1) Igniter connector
(2) Noise filter connector
(3) High-tension cord
(b) Remove the two bolts, the ignition coil, igniter and bracket assembly.

8. REMOVE RADIATOR
9. REMOVE ALTERNATOR
10. REMOVE ALTERNATOR BELT ADJUSTING BAR
11. REMOVE RADIATOR RESERVOIR TANK
12. DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY
13. (A/T) DISCONNECT THROTTLE CABLE FROM THROTTLE BODY
14. (w/ CRUISE CONTROL SYSTEM) REMOVE CRUISE CONTROL ACTUATOR AND VACUUM PUMP

(w/ A.B.S.)
(a) Remove the dust cover.
(b) Disconnect the following hoses and connector:
(1) Actuator vacuum hoses
(2) Actuator connector

(c) Remove the four bolts, actuator and bracket.
(d) Disconnect the vacuum pump connector.
(e) Remove the three bolts, vacuum pump and bracket.

(w/o A.B.S.)
(a) Disconnect the following the hose and connectors:
(1) Actuator vacuum hose from air intake chamber
(2) Actuator connector
(3) Vacuum pump connector
(4) Vacuum switch connector
(b) Remove the three bolts, the actuator, vacuum pump and vacuum switch assembly.

15. REMOVE AIR CLEANER ASSEMBLY
(a) Disconnect the following connector and hoses:
(1) Air flow meter connector
(2) ISC valve air hose
(3) Vacuum pipe air hose
(b) Disconnect the four air cleaner cap clips.
(c) Disconnect the air cleaner hose, and remove the air cleaner cap, hoses, and air flow meter assembly.
(d) Remove the air cleaner element.
(e) Remove the three bolts and air cleaner case.

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. DISCONNECT VACUUM HOSES
(a) Brake booster vacuum hose from air intake chamber
(b) A/C control valve vacuum hose from air intake chamber
(c) A/C control valve vacuum hose from vacuum pipe (on air intake chamber)
(d) Charcoal canister vacuum hose from vacuum pipe (on air intake chamber)

18. DISCONNECT GROUND STRAP FROM TRANSAXLE

19. DISCONNECT HEATER HOSES
20. DISCONNECT FUEL HOSE

CAUTION: Catch leaking fuel in a container.

21. (M/T) REMOVE STARTER

Fig. 5 Clutch Release Cylinder:

22. (M/T) REMOVE CLUTCH RELEASE CYLINDER AND TUBE CLAMP WITHOUT DISCONNECTING TUBE
23. DISCONNECT SPEEDOMETER CABLE
24. DISCONNECT TRANSAXLE CONTROL CABLE
25. DISCONNECT ENGINE WIRE FROM CABIN
(a) Remove the under cover.
(b) Remove the glove compartment box.
(c) Disconnect the following connectors:
(1) Three engine & ECT ECU connectors
(2) Circuit opening relay connector
(3) Cowl wire connector
(4) Instrument panel wire connector
(d) Pull out the engine wire from the cowl panel.

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

27. REMOVE FRONT EXHAUST PIPE
(a) Remove the two pipe stay bolts.
(b) Remove the two bolts and nuts, and disconnect the front pipe from the center pipe. Remove the gasket.
(c) Remove the three nuts, front pipe and gasket.

Fig. 6 A/C Compressor Removal:

28. 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 from the radiator support.

29. REMOVE DRIVE SHAFTS
30. REMOVE PS PUMP WITHOUT DISCONNECTING HOSES

HINT: Put aside the pump and suspend it from the cowl.

31. REMOVE ENGINE MOUNTING CENTER MEMBER
- Remove the eight bolts, two nuts and center member.

32. REMOVE FRONT ENGINE MOUNTING INSULATOR AND BRACKET
(a) Remove the nut, through bolt and mounting insulator.
(b) Remove the three bolts and mounting bracket.

33. REMOVE CENTER ENGINE MOUNTING INSULATOR AND BRACKET ASSEMBLY
- Remove the three bolts, the mounting bracket and insulator assembly.

34. REMOVE REAR ENGINE MOUNTING INSULATOR AND BRACKET
(a) Remove the nut, through bolt and mounting insulator.
(b) Remove the three bolts and mounting bracket.

35. REMOVE PS OIL RESERVOIR TANK WITHOUT DISCONNECTING HOSES
- Remove the two bolts and reservoir tank.
- Disconnect the ground strap.

Fig. 7 RH Engine Mounting Stays:

36. REMOVE ENGINE RH MOUNTING STAYS
(a) Remove the three bolts and No.1 mounting stay.
(b) Remove the bolt, nut and No.2 mounting stay.

37. REMOVE ENGINE LH MOUNTING STAY

(M/T) Remove the bolt, two nuts and mounting stay.

(A/T) Remove the three nuts and mounting stay.

38. REMOVE ENGINE AND TRANSAXLE ASSEMBLY FROM VEHICLE

(a) Attach the engine hoist chain to the engine hangers.
(b) (w/ A.B.S.) Remove the clamp bolts of the PS oil cooler pipes.

(d) Remove the through bolt, nut, four bolts 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 neutmi 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.

39. (A/T) REMOVE STARTER
40. SEPARATE ENGINE AND TRANSAXLE

INSTALLATION OF ENGINE
1. ASSEMBLE ENGINE AND TRANSAXLE
2. (A/T) INSTALL STARTER

3. INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN VEHICLE
(a) Attach the engine chain hoist 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.

(d) Attach the RH mounting insulator to the mounting bracket and body, and temporarily install the bolt and four nuts.
(e) Temporarily install the No.2 mounting stay bolt (A).

(f) Install the LH mounting backet to the transaxle case with the three bolts. Torque the bolts.
Torque: 530 kg.cm (38 ft.lb, 52 N.m)

(g) Attach the LH mounting insulator to the mounting bracket with the three bolts, and install and torque the four bolts and through bolt.
Torque:
Bolt: 530 kg.cm (38 ft.lb, 52 N.m)
Through bolt: 890 kg.cm (64 ft.lb, 87 N.m)

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

(i) Remove the engine hoist chain from the engine.
(j) (w/ A.B.S.) Install the two clamp bolts of the PS oil cooler pipes.

Fig. 7 RH Engine Mounting Stays:

4. INSTALL ENGiNE RH MOUNTING STAYS
(a) Install the No.1 mounting stay with the three bolts. Torque the bolts.
Torque: 530 kg.cm (38 ft.lb, 52 N.m)

(b) Install the No.2 mounting stay with the bolt and nut. Torque the bolt and nut.
Torque:
Bolt: 670 kg.cm (48 ft.lb, 66 N.m)
Nut: 530 kg.cm (38 ft.lb, 52 N.m)

5. INSTALL ENGINE LH MOUNTING STAY

(M/T) Install the mounting stay with the bolt and two nuts. Torque the bolt and nuts.
Torque:
Nut: 530 kg.cm (38 ft.lb, 52 N.m)
Bolt: 195kg.cm (14 ft.lb, 19 N.m)

(A/T) Install the mounting stay with the three nuts. Torque the nuts.
Torque:
12 mm nut 210 kg.cm (15 ft.lb, 21 N.m)
14 mm nut 530 kg.cm (38 ft.lb, 52 N.m)

6. INSTALL PS OIL RESERVOIR TANK
- Install the reservoir tank with the two bolts. Connect the ground strap.

7. INSTALL FRONT ENGINE MOUNTING BRACKET AND INSULATOR
(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 a new nut.

8. INSTALL CENTER ENGINE MOUNTING BRACKET AND INSULATOR ASSEMBLY
- Install the mounting bracket and insulator assembly with the three bolts. Torque the bolts.
Torque: 530 kg.cm (38 ft.lb, 61 N.m)

9. INSTALL REAR ENGINE MOUNTING BRACKET AND INSULATOR
(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 a new nut.

10. 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 holding the insulators (front, center and rear) to the center member.
Torque: 740 kg.cm (54 ft.lb, 73 N.m)
(c) Torque the mounting insulator through bolts (front and rear).
Torque: 895 kg.cm (64 ft.lb, 87 N.m)

11. INSTALL PS PUMP
12. INSTALL DRIVE SHAFTS
13. (w/ A/C) INSTALL A/C COMPRESSOR
(a) Install the compressor with the four bolts.
(b) Connect the two connectors.

14. INSTALL FRONT EXHAUST PIPE
(a) Place two new gaskets on 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 two pipe stay bolts.

15. INSTALL SUSPENSION LOWER CROSSMEMBER
- 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.

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)

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

16. CONNECT ENGINE WIRE TO CABIN
(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 connector
(c) Install the glove compartment box.
(d) Install the under cover.

17. CONNECT TRANSAXLE CONTROL CABLE(S)
18. CONNECT SPEEDOMETER CABLE

Fig. 5 Clutch Release Cylinder:

19. (M/T) INSTALL CLUTCH RELEASE CYLINDER AND TUBE CLAMP
20. (M/T) INSTALL STARTER
21. CONNECT FUEL HOSES

22. CONNECT HEATER HOSES
23. CONNECT GROUND STRAP TO TRANSAXLE
24. CONNECT VACUUM HOSES
(a) Brake booster vacuum hose to air intake chamber
(b) A/C idle-up vacuum hose to air intake chamber
(c) A/C idle-up vacuum hose to vacuum pipe (on air intake chamber)
(d) Charcoal canister vacuum hose to vacuum pipe (on air intake chamber)

25. CONNECT WIRES AND CONNECTORS
(a) Check connector
(b) Ground straps from OH fender apron
(c) Connectors from relay box
(d) Engine room wire connector

26. 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 following connector and hoses:
(1) Air flow meter connector
(2) ISC valve air hose
(3) Vacuum pipe air hose

27. (w/ CRUISE CONTROL SYSTEM) INSTALL CRUISE CONTROL ACTUATOR
(w/ABS)

(a) Install the vacuum pump and bracket with the three bolts.
(b) Connect the vacuum pump connector.

(c) Install the actuator and bracket with the four bolts.
(d) Connect the following hoses and connector:
(1) Actuator vacuum hoses
(2) Actuator connector
(e) Install the dust cover.

(w/o ABS)

(a) Install the actuator, vacuum pump and vacuum switch assembly with the three bolts.
(b) Connect the following the hose and connectors:
(1) Actuator vacuum hose from air intake chamber
(2) Actuator connector
(3) Vacuum pump connector
(4) Vacuum switch connector

28. (A/T) INSTALL THROTTLE CABLE, AND ADJUST IT
29. INSTALL ACCELERATOR CABLE, AND ADJUST IT
30. INSTALL RADIATOR RESERVOIR TANK
31. INSTALL ALTERNATOR BELT ADJUSTING BAR
32. INSTALL ALTERNATOR
33. INSTALL RADIATOR

34. INSTALL IGNITION COIL, IGNITER AND BRACKET ASSEMBLY
(a) Install the ignition coil, igniter and bracket assembly with the two bolts.
(b) Connect the following cord and connectors:
(1) Igniter connector
(2) Noise filter connector
(3) High-tension cord

35. INSTALL BATTERY
- Connect the ground strap.

36. FILL WITH ENGINE COOLANT

Capacity (w/ Heater):
M/T: 9.5 liters (10.0 US qts, 8.4 Imp. qts)
A/T: 9.4 liters (9.9 US qts, 8.3 Imp. qts)

37. 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: 4.6 liters (4.8 US qts, 4.0 Imp. qts)

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

Drive belt tension:
New belt: 175 ± 5 lb
Used belt: 115 ± 20 lb

(b) Adjust PS pump drive belt.

Drive belt tension:
New belt: 125 ± 25 lb
Used belt: 8O ± 20 lb

(c) Adjust the ignition timing.

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

(d) Adjust the valve clearance.

Valve clearance:
Intake: 0.13 - 0.23 mm (0.005 - 0.009 in.)
Exhaust: 0.27 - 0.37 mm (0.011 - 0.015 in.)

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