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Oil Pan

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Drain the engine oil from the engine crankcase.
  3. Remove the exhaust flex pipe retaining nuts from the exhaust manifold.
  4. Remove the exhaust flex pipe retaining nuts from the catalytic converter or the connecting pipe.
  5. Remove the exhaust flex pipe.

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  6. Remove the oil pan flange-to-transaxle retaining bolts.

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  7. Remove the oil pan retaining bolts.
  8. Remove the oil pan from the engine block.

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Cleaning Procedure

  1. Clean the oil pan sealing surface.
  2. Clean the engine block sealing surface.
  3. Clean the oil pan retaining bolts.
  4. Clean the oil pan attaching bolt holes in the engine block.
  5. Clean the oil pan scraper.

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Installation Procedure

  1. Coat the new oil pan gasket with sealant.

    2. Important : Install the oil pan within 5 minutes after applying the liquid gasket to the oil pan.

  2. Install the oil pan to the engine block.
  3. Install the oil pan retaining bolts.

    4. Tighten
    Tighten the oil pan retaining bolts to 10 N•m (89 lb-in).


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  4. Install the oil pan flange-to-transaxle retaining bolts.

    5. Tighten
    Tighten the oil pan flange-to-transaxle bolts to 40 N•m (30 lb-ft).


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  5. Install the exhaust flex pipe.
  6. Install the exhaust flex pipe retaining nuts to the exhaust manifold.

    7. Tighten
    Tighten the exhaust flex pipe-to-exhaust manifold retaining nuts to 35 N•m (26 lb-ft).

  7. Install the exhaust flex pipe retaining nuts to the catalytic converter or the connecting pipe.

    8. Tighten
    Tighten the exhaust flex pipe-to-catalytic converter or connecting pipe retaining nuts to 35 N•m (26 lb-ft).

  8. Connect the negative battery cable.
  9. Install the oil pan drain plug.

    10. Tighten
    Tighten the oil pan drain plug to 35 N•m (26 lb-ft).

  10. Refill the engine crankcase with engine oil.

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Oil Pump

Tools Required

KM-498-B Pressure Gauge
KM-135 Adapter

Engine Oil Pressure Inspection Procedure

  1. Remove the right front wheel well oil pan scraper. Refer to Section 9R, Body Front End.
  2. Disconnect the oil pressure switch connector.

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  3. Install the adapter KM-135 in place of the oil pressure switch.
  4. Connect the pressure gauge KM-498-B to the adapter.
  5. Start the engine and check the oil pressure at idle speed and engine temperature of 80°C (176°F). The minimum oil pressure should be 30 kPa (4.35 psi).
  6. Stop the engine and remove the pressure gauge KM-498-B and the adapter KM-135.

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  7. Install the oil pressure switch.

    8. Tighten
    Tighten the oil pressure switch to 40 N•m (30 lb-ft).

  8. Connect the electrical connector to the oil pressure switch.
  9. Install the right front wheel well oil pan scraper. Refer to Section 9R, Body Front End.
  10. Check the oil level. Add oil until it reaches the full mark.

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Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the timing belt. Refer to "Timing Belt" in this section.
  3. Remove the rear timing belt cover. Refer to "Rear Timing Belt Cover" in this section.
  4. Disconnect the oil pressure switch connector.

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  5. Remove the oil pan. Refer to "Oil Pan" in this section.
  6. Remove the oil suction pipe and support bracket bolts.
  7. Remove the oil suction pipe.

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  8. Remove the oil pump retaining bolts.
  9. Carefully separate the oil pump and gasket from the engine block and oil pan.
  10. Remove the oil pump.

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Inspection Procedure

  1. Clean the oil pump and the engine block gasket mating surface areas.
  2. Remove the safety relief valve bolt.
  3. Remove the safety relief valve and the spring.
  4. Remove the oil pump-to-crankshaft seal.

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  5. Remove the oil pump rear cover bolts.
  6. Remove the rear cover.
  7. Clean the oil pump housing and all the oil pump parts.
  8. Inspect all the oil pump parts for signs of wear. Refer to "Engine Specifications" in this section. Replace the worn oil pump parts.

    9. Notice : Pack the oil pump gear cavity with petroleum jelly to ensure an oil pump prime, or engine damage could result.

  9. Coat all the oil pump parts with clean engine oil. Install the oil pump parts.
  10. Apply Loctite® 242 to the oil pump rear cover bolts and install the cover and bolts.

    11. Tighten
    Tighten the oil pump rear cover bolts to 6 N•m (53 lb-in).

  11. Install the safety relief valve, spring, washer and bolt.

    12. Tighten
    Tighten the safety relief valve bolt to 30 N•m (22 lb-ft).


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Installation Procedure

  1. Apply Loctite® 242 to the oil pump bolts and room temperature vulcanizing (RTV) sealant to the new oil pump gasket.
  2. Install the gasket to the oil pump and install the oil pump to the engine block with the bolts.

    3. Tighten
    Tighten the oil pump retaining bolts to 10 N•m (89 lb-in).


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  3. Install a new oil pump-to-crankshaft seal. Coat the lip of the seal with a thin coat of grease.

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  4. Coat the threads of the oil suction pipe and support bracket bolts with Loctite® 242.
  5. Install the oil suction pipe and the bolts.

    6. Tighten
    Tighten the oil suction pipe bolts to 10 N•m (89 lb-in) and support bracket bolts to 6 N•m (53 lb-in).


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  6. Install the oil pan. Refer to "Oil Pan" in this section.
  7. Connect the oil pressure switch connector.
  8. Install the rear timing belt cover. Refer to "Rear Timing Belt Cover" in this section.
  9. Install the timing belt. Refer to "Timing Belt" in this section.
  10. Connect the negative battery cable.

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Engine Mount

Tools Required

J-28467-B Engine Assembly Support Fixture
X-28467-560 Engine Assembly Support Channel

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Support the engine assembly using the engine assembly support fixture J-28467-B, and the engine assembly support channel X-28467-560.
  3. Disconnect the manifold air temperature (MAT) sensor connector.
  4. Disconnect the air cleaner outlet hose from the throttle body.
  5. Remove the air cleaner housing bolts.
  6. Remove the air cleaner housing.

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  7. Remove the right front splash shield. Refer to Section 9R, Body Font End.
  8. Remove the engine mount bracket retaining bolts.
  9. Remove the engine mount bracket.
  10. Remove the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump.

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  11. Remove the front timing belt cover bolts.
  12. Align the crankshaft pulley timing mark with the pointer, and the camshaft gears with the timing marks on the rear cover, by turning the crankshaft gear bolt.
  13. Loosen the timing belt automatic tensioner bolt.
  14. Turn the hex-key tab to relieve belt tension.
  15. Remove the timing belt idler pulley bolt and nut.
  16. Remove the timing belt idler pulley.
  17. Remove the engine mount retaining bolts.
  18. Remove the engine mount.

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Installation Procedure

  1. Install the engine mount.
  2. Install the engine mount retaining bolts.

    3. Tighten
    Tighten the engine mount retaining bolts to 45 N•m (33 lb-ft).


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  3. Install the timing belt idler pulleys.
  4. Install the timing belt idler pulley bolt and nut.

    5. Tighten
    Tighten the timing belt idler pulley bolt and nut to 25 N•m (18 lb-ft).

  5. Tension the timing belt by turning the timing belt automatic tensioner hex-key tab counterclockwise until the pointer is aligned to the indicator.

    6. Tighten
    Tighten the timing belt automatic tensioner bolt to 25 N•m (18 lb-ft).


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  6. Install the front timing belt cover.
  7. Install the front timing belt cover bolts.

    8. Tighten
    Tighten the front timing belt cover bolts to 6 N•m (53 lb-in).

  8. Install the engine mount bracket and retaining bolts.

    9. Tighten
    Tighten the engine mount bracket retaining bolts to 55 N•m (41 lb-ft).

  9. Remove the engine assembly support fixture J-28467-B, and the channel X-28467-560.
  10. Install the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump.
  11. Connect the negative battery cable.

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Intake Manifold

Removal Procedure

  1. Remove the fuel pump fuse.
  2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.
  3. Disconnect the negative battery cable.
  4. Disconnect the charcoal canister purge (CCP) and exhaust gas recirculation (EGR) solenoid from the intake manifold and loosen the bracket bolt.
  5. Drain the engine coolant. Refer to Section 1D, Engine Cooling.

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  6. Disconnect the manifold air temperature sensor (MAT) connector.
  7. Disconnect the air cleaner outlet hose from the throttle body.

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  8. Disconnect the idle air control (IAC) valve connector.
  9. Disconnect the throttle position sensor (TPS) connector.
  10. Disconnect the manifold absolute pressure (MAP) sensor connector.
  11. Disconnect the coolant hoses at the throttle body.

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  12. Disconnect all of the necessary vacuum hoses, including the vacuum hose at the fuel pressure regulator and the brake booster vacuum hose at the intake manifold.
  13. Disconnect the throttle cable from the throttle body and the intake manifold.
  14. Remove the throttle cable bracket bolts from the intake manifold.
  15. Remove the throttle cable bracket.
  16. Remove the generator-to-intake manifold strap bracket bolts and strap.

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  17. Remove the fuel rail as an assembly. Refer to Section 1F, Engine Controls.
  18. Remove the generator-to-intake manifold support bracket bolts.
  19. Remove the generator-to-intake manifold support bracket.
  20. Remove the intake manifold support bracket bolt at the engine block and the intake manifold.
  21. Remove the intake manifold support bracket.

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  22. Remove the intake manifold retaining bolt and nuts in the sequence shown.
  23. Remove the intake manifold.
  24. Remove the intake manifold gasket.
  25. Clean the sealing surfaces of the intake manifold and the cylinder head.

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Installation Procedure

  1. Install the intake manifold gasket.
  2. Install the intake manifold.
  3. Install the intake manifold retaining bolt and nuts in the sequence shown.

    4. Tighten
    Tighten the intake manifold retaining bolt and nuts to 22 N•m (16 lb-ft).

  4. Install the generator-to-intake manifold strap bracket and bolts.

    5. Tighten
    Tighten the generator-to-intake manifold strap bracket bolts to 22 N•m (16 lb-ft).


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  5. Install the intake manifold support bracket.
  6. Install the intake manifold support bracket upper bolts to the intake manifold.

    7. Tighten
    Tighten the intake manifold support bracket upper bolts to the intake manifold to 25 N•m (18 lb-ft).

  7. Install the intake manifold support bracket lower bolt to the engine block.

    8. Tighten
    Tighten the intake manifold support bracket lower bolt to the engine block to 25 N•m (18 lb-ft).

  8. Install the generator-to-intake manifold support bracket and bolts.

    9. Tighten
    Tighten the generator-to-intake manifold support bracket bolts to 37 N•m (27 lb-ft).


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  9. Install the fuel rail and injector cover as an assembly. Refer to Section 1F, Engine Controls.
  10. Install the throttle cable bracket.
  11. Install the throttle cable bracket bolts.

    12. Tighten
    Tighten the throttle cable bracket bolts to 8 N•m (71 lb-in).

  12. Connect the throttle cable to the intake manifold and the throttle body.
  13. Connect all of the necessary vacuum lines that were previously disconnected.

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  14. Connect the MAP sensor connector.
  15. Connect the coolant hoses to the throttle body.
  16. Connect the IAC valve connector.
  17. Connect the TPS connector.

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  18. Connect the air cleaner outlet hose to the throttle body.
  19. Connect the MAT sensor connector.
  20. Connect the CCP and EGR solenoid at the intake manifold and tighten the bracket bolt.

    21. Tighten
    Tighten the charcoal canister purge and exhaust gas recirculation solenoid bracket bolt to 5 N•m (44 lb-in).

  21. Install the fuel pump fuse.
  22. Connect the negative battery cable.
  23. Refill the engine cooling system. Refer to Section 1D, Engine Cooling.

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Exhaust Manifold

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the oxygen (O2) sensor connector, if equipped.
  3. Remove the exhaust manifold heat shield bolts.
  4. Remove the exhaust manifold heat shield.

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  5. Remove the exhaust flex pipe retaining nuts from the exhaust manifold studs.

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  6. Remove the exhaust manifold retaining nuts in the sequence shown.
  7. Remove the exhaust manifold.
  8. Remove the exhaust manifold gasket.
  9. Clean the sealing surfaces of the exhaust manifold and the cylinder head.

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Installation Procedure

  1. Install the exhaust manifold gasket.
  2. Install the exhaust manifold.
  3. Install the exhaust manifold retaining nuts and tighten in the sequence shown.

    4. Tighten
    Tighten the exhaust manifold retaining nuts 22 N•m (16 lb-ft).


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  4. Install the exhaust flex pipe retaining nuts to the exhaust manifold studs.

    5. Tighten
    Tighten the exhaust flex pipe-to-exhaust manifold retaining nuts to 35 N•m (26 lb-ft).


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  5. Install the exhaust manifold heat shield.
  6. Install the exhaust manifold heat shield bolts.

    7. Tighten
    Tighten the exhaust manifold heat shield bolts to 8 N•m (71 lb-in).

  7. Connect the O2 sensor connector, if equipped.
  8. Connect the negative battery.

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Camshaft Gears

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the timing belt. Refer to "Timing Belt" in this section.
  3. Remove the spark plug cover bolts.
  4. Remove the spark plug cover.
  5. Disconnect the ignition wires from the spark plugs.
  6. Disconnect the breather tubes from the camshaft cover.

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  7. Remove the camshaft cover bolts.
  8. Remove the camshaft cover washers.
  9. Remove the camshaft cover and the camshaft cover gasket.

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    Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts.

  10. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt.
  11. Remove the intake camshaft gear.
  12. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt.
  13. Remove the exhaust camshaft gear.

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Installation Procedure

    Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts.

  1. Install the intake camshaft gear.
  2. While holding the intake camshaft firmly in place, install the intake camshaft gear bolt.

    3. Tighten
    Tighten the intake camshaft gear bolt to 50 N•m (37 lb-ft) plus 60 degrees and 15 degrees using the angular torque gauge KM-470-B.

  3. Install the exhaust camshaft gear.
  4. While holding the exhaust camshaft firmly in place, install the exhaust camshaft gear bolt.

    5. Tighten
    Tighten the exhaust camshaft gear bolt to 50 N•m (37 lb-ft) plus 60 degrees and 15 degrees using the angular torque gauge KM-470-B.


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  5. Apply a small amount of gasket sealant to the corners of the front camshaft caps and to the top of the rear camshaft cover-to-cylinder head seal.
  6. Install the camshaft cover and the camshaft cover gasket.
  7. Install the camshaft cover washers.
  8. Install the camshaft cover bolts.

    9. Tighten
    Tighten the camshaft cover bolts to 8 N•m (71 lb-in).


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  9. Connect the crankcase breather tubes to the camshaft cover.
  10. Connect the ignition wires to the spark plugs.
  11. Install the spark plug cover.
  12. Install the spark plug cover bolts.

    13. Tighten
    Tighten the spark plug cover bolts to 8 N•m (71 lb-in).

  13. Install the timing belt. Refer to "Timing Belt" in this section.
  14. Connect the negative battery cable.

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Rear Timing Belt Cover

Tools Required

KM-470-B Angular Torque Gauge

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the timing belt. Refer to "Timing Belt" in this section.
  3. Remove the camshaft gears. Refer to "Camshaft Gears" in this section.
  4. Remove the timing belt automatic tensioner bolt.
  5. Remove the timing belt automatic tensioner.

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  6. Remove the timing belt idler pulley bolt and nut.
  7. Remove the timing belt idler pulleys.
  8. Remove the engine mount retaining bolts.
  9. Remove the engine mount.
  10. Remove the crankshaft gear bolt.
  11. Remove the crankshaft gear.

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  12. Remove the rear timing belt cover bolts.
  13. Remove the rear timing belt cover.

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Installation Procedure

  1. Install the rear timing belt cover.
  2. Install the rear timing belt cover bolts.

    3. Tighten
    Tighten the rear timing belt cover bolts to 7 N•m (62 lb-in).

  3. Install the engine mount and retaining bolts.

    4. Tighten
    Tighten the engine mount retaining bolts to 45 N•m (33 lb-ft).


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  4. Install the timing belt idler pulleys.
  5. Install the timing belt idler pulley bolt and nut.

    6. Tighten
    Tighten the timing belt idler pulley bolt to 25 N•m (18 lb-ft).
    Tighten the timing belt idler pulley nut to 25 N•m (18 lb-ft).

  6. Install the crankshaft timing belt drive gear and bolt.

    7. Tighten
    Tighten the crankshaft gear bolt to 145 N•m (107 lb-ft) plus 30 degrees and plus 15 degrees using the angular torque gauge KM-470-B.


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  7. Install the timing belt automatic tensioner and bolt.
  8. Install the camshaft gears. Refer to "Camshaft Gears" in this section.
  9. Install the timing belt and timing belt cover. Refer to "Timing Belt" in this section.
  10. Connect the negative battery cable.

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Engine

Removal Procedure

  1. Remove the fuel pump fuse.
  2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.
  3. Remove the hood. Refer to Section 9R, Body Front End.
  4. Drain the engine oil.
  5. Disconnect the negative battery cable.

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  6. Discharge the air conditioning (A/C) system, if equipped. Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning Systems.
  7. Disconnect the manifold air temperature (MAT) sensor connector.
  8. Remove the air cleaner outlet hose from the throttle body and air cleaner housing.
  9. Disconnect the breather tubes from the camshaft cover.
  10. Remove the right front wheel. Refer to Section 2E, Tires and Wheels.
  11. Remove the right front wheel well splash shield. Refer to Section 9R, Body Font End.
  12. Remove the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump.

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  13. Drain the engine coolant. Refer to Section 1D, Engine Cooling.
  14. Remove the cooling system radiator and the engine cooling fans. Refer to Section 1D, Engine Cooling.
  15. Disconnect the upper radiator hose from the thermostat housing.
  16. Disconnect the power steering return hose from the power steering pump.
  17. Disconnect the power steering pressure hose from the power steering pump.
  18. Disconnect the electrical connector at the direct ignition system (DIS) coil and the electronic control module (ECM) ground terminal and at the starter motor.

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  19. Disconnect the oxygen (O2) sensor connector, if equipped.
  20. Disconnect the idle air control (IAC) valve connector.
  21. Disconnect the throttle position sensor (TPS) connector.
  22. Disconnect the engine coolant temperature sensor (CTS) connector.
  23. Disconnect the CTS connector.
  24. Disconnect the generator voltage regulator connector and power lead.

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  25. Disconnect all of the necessary vacuum lines, including the brake booster vacuum hose.
  26. Disconnect the fuel return line at the fuel rail.
  27. Disconnect the fuel feed line at the fuel rail.
  28. Remove the fuel rail and injector channel cover as an assembly. Refer to Section 1F, Engine Controls.

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  29. Disconnect the throttle cable from the throttle body and the intake manifold bracket.
  30. Disconnect the coolant hose at the throttle body.
  31. Disconnect the heater outlet hose at the coolant pipe.
  32. Disconnect the coolant bypass hose from the cylinder head.
  33. Disconnect the surge tank coolant hose from the coolant pipe.
  34. Disconnect the lower radiator hose from the coolant pipe.
  35. Disconnect the starter solenoid "S" terminal wire and power lead.
  36. Remove the A/C compressor. Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning Systems.

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  37. Remove the exhaust flex pipe retaining nuts from the exhaust manifold studs.
  38. Remove the exhaust flex pipe retaining nuts from the catalytic converter or the connecting pipe.
  39. Remove the exhaust flex pipe.

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  40. Remove the crankshaft pulley bolts.
  41. Remove the crankshaft pulley.
  42. Disconnect the vacuum lines at the charcoal canister purge solenoid.
  43. Disconnect the electrical connector at the charcoal canister purge (CCP) and the exhaust gas recirculation (EGR) solenoid.
  44. Disconnect the electrical connector at the oil pressure switch.
  45. Disconnect the crankshaft position sensor (CPS) connector.
  46. Disconnect the knock sensor connector.

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  47. Remove the transaxle torque converter bolts, if automatic transaxle equipped.
  48. Remove the transaxle bell housing bolts and the oil pan flange bolts.
  49. Support the transaxle with a floor jack.
  50. Install the engine lifting device.

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  51. Disconnect the right engine mount bracket from the engine mount by removing the retaining bolt.
  52. Remove the right engine mount bracket from the engine block and frame mount. Refer to Section 5B, Five Speed Manual Transaxle, or Section 5A, Automatic Transaxle.
  53. Separate the engine block from the transaxle. Remove the engine.

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Installation Procedure

  1. Install the engine into the engine compartment.
  2. Align the engine alignment pins to the transaxle.
  3. Install the transaxle bell housing bolts.

    4. Tighten
    Tighten the transaxle bell housing bolts to 75 N•m (55 lb-ft).

  4. Install the oil pan flange-to-transaxle bolts.

    5. Tighten
    Tighten the oil pan flange-to-transaxle bolts to 40 N•m (30 lb-ft).


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  5. Install the right engine mount to the engine block mount and the frame mount.
  6. Install the right engine mount bracket retaining bolts and nuts.

    7. Tighten
    Tighten the engine mount bracket retaining bolts and nuts to 55 N•m (41 lb-ft).


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  7. Remove the floor jack used for support of the transmission.
  8. Remove the engine lifting device.
  9. Install the transaxle torque converter bolts, if automatic transaxle equipped.

    10. Tighten
    Tighten the transaxle torque converter bolts to 60 N•m (44 lb-ft).


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  10. Connect the vacuum lines at the CCP solenoid.
  11. Connect the electrical connector to the CCP and the EGR solenoid.
  12. Connect the oil pressure switch connector.
  13. Install the crankshaft pulley.
  14. Install the crankshaft pulley bolts.

    15. Tighten
    Tighten the crankshaft pulley bolts to 20 N•m (15 lb-ft) using a torque wrench.


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  15. Connect the CPS connector.
  16. Install the exhaust flex pipe.
  17. Install the exhaust flex pipe retaining nuts to the exhaust manifold studs.

    18. Tighten
    Tighten the exhaust flex pipe-to-exhaust manifold retaining nuts to 35 N•m (26 lb-ft).


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  18. Install the exhaust flex pipe retaining nuts to the catalytic converter or the connecting pipe.

    19. Tighten
    Tighten the exhaust flex pipe-to-catalytic converter or connecting pipe retaining nuts to 35 N•m (26 lb-ft).

  19. Connect the power steering pressure hose.
  20. Connect the power steering return hose.
  21. Install the A/C compressor, if equipped. Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System.

    22. J3B11C22
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  22. Install the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump.
  23. Install the right front wheel well splash shield.
  24. Install the right front wheel. Refer to Section 2E, Tires and Wheels.
  25. Connect the fuel feed line to the fuel rail.
  26. Connect the fuel return line to fuel rail.
  27. Install the fuel rail and injector channel cover as an assembly. Refer to Section 1F, Engine Controls.

    28. J3B11C13
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  28. Connect all of the necessary vacuum lines including the brake booster vacuum hose.
  29. Connect the O2 sensor connector, if equipped.
  30. Connect the starter solenoid "S" terminal wire and power lead.
  31. Connect the generator voltage regulator connector.
  32. Connect the CTS connector.
  33. Connect the engine CTS connector.
  34. Connect the TPS connector.
  35. Connect the IAC valve connector.
  36. Connect the MAP sensor connector.
  37. Connect the knock sensor, if necessary

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  38. Connect the electrical connector at the DIS ignition coil and the ECM ground terminal and at the starter motor.
  39. Install the air cleaner outlet hose between the throttle body and the air cleaner housing.
  40. Connect the breather tubes to the camshaft cover.
  41. Connect the MAT sensor connector.
  42. Install the cooling system radiator and the engine cooling fans. Refer to Section 1D, Engine Cooling.

    43. J3B11D06
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  43. Connect the lower radiator hose to the coolant pipe.
  44. Connect the upper radiator hose to the thermostat housing.
  45. Connect the heater inlet hose to the cylinder head.
  46. Connect the heater outlet hose to the coolant pipe.
  47. Connect the coolant surge tank hose to the coolant pipe.
  48. Connect the coolant hose to the throttle body.

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  49. Connect the throttle cable to the throttle body and the intake manifold bracket.
  50. Install the fuel pump fuse.
  51. Connect the negative battery cable.
  52. Refill the engine crankcase with engine oil.
  53. Refill the engine coolant system. Refer to Section 1D, Engine Cooling.
  54. Bleed the power steering system. Refer to Section 6A, Power Steering.
  55. Refill the A/C refrigerant system, if equipped. Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System.
  56. Install the hood. Refer to Section 9R, Body Front End.

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Pistons and Rods

Tools Required

J-8037 Universal Piston Ring Compressor
J-8087 Cylinder Bore Check Gauge
KM-427 Piston Pin Service Set
KM-470-B Angular Torque Gauge

Removal Procedure

  1. Remove the cylinder head with the intake manifold and exhaust manifold attached. Refer to "Cylinder Head and Gasket" in this section.

  2. Remove the oil pan. Refer to "Oil Pan" in this section.
  3. Remove the oil suction pipe bolts and support bracket bolts.
  4. Remove the oil suction pipe.
  5. Remove the crankshaft bearing bridge and the oil pan scraper bolts.
  6. Remove the crankshaft bearing bridge and the oil pan scraper.

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  7. Move the piston to the bottom of the piston stroke.
  8. Mark the connecting rod cap for position.
  9. Remove the connecting rod cap bolts.
  10. Remove the connecting rod cap and the lower connecting rod bearing.
  11. Remove the upper piston connecting rod bearing.
  12. Ridge ream the cylinder wall.

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    Caution : Use care when handling the piston. Worn piston rings are sharp and may cause injury.

  13. Remove the piston.
  14. Use a piston ring expander tool to expand the piston rings.
  15. Remove the piston rings.

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  16. Remove the piston pin from the piston and connecting rod assembly using the piston pin service set KM-427.
  17. Separate the piston from the connecting rod.

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Inspection Procedure

  1. Inspect the connecting rod for bending or twisting. If the connecting rod is bent or twisted, replace the connecting rod.
  2. Inspect the connecting rod bearings.
  3. Inspect the connecting rod lower end for wear.
  4. Inspect the connecting rod upper end for scoring.
  5. Inspect the crankshaft rod bearing journal for wear. Refer to "Engine Specifications" in this section.
  6. Inspect the piston for scoring, cracks, and wear.
  7. Inspect the piston for taper using a micrometer.

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  8. Inspect the piston for fit to the connecting rod.

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  9. Inspect the engine block deck surface for flatness using a straight edge and a feeler gauge. Refer to "Engine Specifications" in this section.
  10. Inspect the bearing bore for concentricity and alignment using cylinder bore check gauge J-8087. Refer to "Engine Specifications" in this section. If the bearing bore is beyond specifications, replace the engine block.
  11. Inspect the engine block cylinder bore for wear, runout, ridging and taper using a bore gauge. Refer to "Engine Specifications" in this section.
  12. Inspect the engine block cylinder bore for glazing. Lightly hone the cylinder bore as necessary.

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Installation Procedure

    Important : For ease of installation of the piston pin, the connecting rod should be heated to 2805C. Heat the upper connecting rod only. Use commercial thermocolor material to determine the correct temperature. When the thermocolor material changes from black to green, the temperature is correct for installation.

  1. Align the notch on the piston and connecting rod so that the proper sides will be facing the front of the engine.
  2. Install the piston pin guide through the piston and the connecting rod.
  3. Coat the piston pin with clean oil.
  4. Install the piston pin into the opposite side of the piston.

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  5. Install the piston pin into the piston and connecting rod assembly using the piston pin service set KM-427.
  6. Select a set of new piston rings.
  7. Measure the piston ring gap using a feeler gauge. Refer to "Engine Specifications" in this section.
  8. Increase the piston ring gap by carefully filing off excess material if the piston ring gap is below specifications.

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  9. Measure the piston ring side clearance using a feeler gauge. Refer to "Engine Specifications'' in this section.
  10. If the piston ring is too thick, try another piston ring.
  11. If no piston ring can be found that fits to specifications, the piston ring may be ground to size with emery paper placed on a sheet of glass.

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  12. Install a piston oil ring, the expander, then the second piston oil ring to the bottom ring groove of the piston.
  13. Install the second compression ring to the middle ring groove of the piston.
  14. Install the top compression ring to the top ring groove of the piston.

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  15. Use a piston ring expander to install the piston rings. Do not expand the piston rings beyond the expansion necessary for installation.
  16. Stagger the piston oil rings, the oil ring rail gaps, the second compression ring, and the top compression ring in relation to the notch on the top of the piston.

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  17. Lubricate the cylinder wall and the piston rings with clean engine oil.
  18. Install the piston using the universal piston ring compressor J-8037 and a wood handle. Guide the lower connecting rod end to prevent damaging the crankshaft journal.
  19. Install the connecting rod cap and bearings. Refer to "Crankshaft Bearings and Connecting Rod Bearings - Gauging Plastic" in this section.

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  20. Install the connecting rod cap bolts.

    21. Tighten
    Tighten the connecting rod bearing cap bolts to 35 N•m (26 lb-ft). Using the angular torque gauge KM-470-B, tighten the bolts one turn of 45 degrees plus one turn of 15 degrees.

  21. Install the crankshaft bearing bridge/oil pan scraper bolts.

    22. Tighten
    Tighten the crankshaft bearing bridge/oil pan scraper bolts to 20 N•m (15 lb-ft) plus 45 degrees using the angular torque gauge KM-470-B.


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  22. Install the oil suction pipe.
  23. Install the oil suction pipe bolts.

    24. Tighten
    Tighten the oil suction pipe bolts to 8 N•m (71 lb-in) and the oil suction pipe bracket bolt to 6 N•m (53 lb-in).

  24. Install the oil pan. Refer to "Oil Pan" in this section.
  25. Install the cylinder head with the intake manifold and exhaust manifold attached. Refer to "Cylinder Head and Gasket" in this section.


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