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J3B11CG3
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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 catalytic converter retaining nuts from the exhaust pipe.

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  4. Remove the lower crossmember bracket.
  5. Remove the exhaust connecting pipe.

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  6. Remove the oil pan bolts to the transaxle case.

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  7. Remove the oil pan retaining bolts to the engine block.
  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.

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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 bolts to the transaxle case.

    5. Tighten
    Tighten the oil pan to the transaxle case bolts to 31 N•m (23 lb-ft).


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  5. Install the exhaust connecting pipe.
  6. Install the catalytic converter retaining nuts to the exhaust pipe.

    7. Tighten
    Tighten the catalytic converter to exhaust pipe retaining nuts to 40 N•m (30 lb-ft).

  7. Install the lower crossmember bracket.
  8. Connect the negative battery cable.
  9. Install the oil pan drain plug.

    10. Tighten
    Tighten the oil pan drain plug to 55 N•m (40 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, wheel well splash shield and engine undercover.
  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 oil pressure switch connector.
  9. Install the right front wheel well splash shield, engine undercover and wheel.
  10. Check the oil level. Pour oil until it reaches the full mark.

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Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the power steering pump, if equipped. Refer to Section 6A, Power Steering System.
  3. Remove the timing belt. Refer to "Timing Belt" in this section.
  4. Remove the rear timing belt cover. Refer to "Rear Timing Belt Cover" in this section.
  5. Disconnect the oil pressure switch connector.

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

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

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  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 8 N•m (71 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 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 bolts.

    6. Tighten
    Tighten the oil suction pipe and support bracket bolts to 10 N•m (89 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. Install the power steering pump, if equipped. Refer to Section 6A, Power Steering System.
  11. Connect the negative battery cable.

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Engine Mount

Tools Required

DW110-060 Engine Support Fixture

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Support the engine assembly using the engine support fixture DW110-060.

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  3. Remove the engine mount bracket attaching bolts/nuts.
  4. Remove the front timing belt cover. Refer to "Timing Belt" in this section.

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  5. Remove the engine mount attaching bolts/nuts.
  6. 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 attaching bolts to 30 N•m (22 lb-ft).

  3. Install the front timing belt cover. Refer to "Timing Belt" in this section.

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  4. Install the engine mount bracket attaching bolts/nuts.

    5. Tighten
    Tighten the engine mount bracket attaching bolts/nuts to 55 N•m (41 lb-ft).


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  5. Remove engine assembly support fixture DW110-060.
  6. Connect the negative battery cable.

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Camshaft Gears

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the engine cover.
  3. Remove the timing belt. Refer to "Timing Belt" in this section.
  4. Disconnect the ignition wires from the spark plugs.
  5. Disconnect the engine ventilation hoses from the camshaft cover.

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  6. Remove the camshaft cover bolts.
  7. 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.

  8. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt.
  9. Remove the intake camshaft gear.
  10. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt.
  11. 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 67.5 N•m (49 lb-ft).

  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 67.5 N•m (49 lb-ft).


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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 bolts.

    8. Tighten
    Tighten the camshaft cover nuts to 10 N•m (89 lb-in).


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  8. Connect the engine ventilation hoses to the camshaft cover.
  9. Connect the ignition wires to the spark plugs.
  10. Install the timing belt. Refer to "Timing Belt" in this section.
  11. Install the engine cover. Refer to "Engine Cover" in this section.
  12. Connect the negative battery cable.

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Rear Timing Belt Cover

Removal Procedure

  1. Remove the timing belt and the timing belt cover. Refer to "Timing Belt" in this section.
  2. Remove the camshaft gears. Refer to "Camshaft Gears" in this section.
  3. Remove the crankshaft gear.
  4. Remove the timing belt automatic tensioner bolts.
  5. Remove the timing belt automatic tensioner.

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  6. Remove the timing belt idler pulley bolt.
  7. Remove the timing belt idler pulley.

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  8. Remove the rear timing belt cover bolts.
  9. 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 10 N•m (89 lb-in).


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  3. Install the timing belt idler pulley.
  4. Install the timing belt idler pulley bolt.

    5. Tighten
    Tighten the timing belt idler pulley bolt to 40 N•m (30 lb-ft).


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  5. Install the timing belt automatic tensioner.
  6. Install the timing belt automatic tensioner bolts.

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

  7. Install the crankshaft gear.

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

  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.

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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. Remove the air cleaner outlet hose from the throttle body and air cleaner housing.
  7. Disconnect the breather tubes from the camshaft cover.
  8. Remove the serpentine accessory drive belt. Refer to Section 6B, Power Steering Pump.
  9. Remove the right front wheel. Refer to Section 2E, Tires and Wheels.
  10. Remove the right front wheel well splash shield.

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  11. Drain the engine coolant. Refer to Section 1D, Engine Cooling.
  12. Remove the cooling system radiator and the engine cooling fans. Refer to Section 1D, Engine Cooling.
  13. Disconnect the upper radiator hose from the thermostat housing.
  14. Disconnect the power steering return hose from the power steering pump. Refer to Section 6A, Power Steering System.
  15. Disconnect the power steering pressure hose from the power steering pump. Refer to Section 6A, Power Steering System.
  16. Disconnect the electrical connector at the direct ignition system (DIS) coil and the electronic control module (ECM) ground terminal at the intake manifold and at the starter motor.

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  17. Disconnect the oxygen (O2) sensor connector, if equipped.
  18. Disconnect the fuel injector harness connectors.
  19. Disconnect the MAT, MAP sensor connectors.
  20. Disconnect the throttle position sensor (TPS) connector.
  21. Disconnect the generator voltage regulator connector and power lead.
  22. Remove the electrical harness clamp bolt.

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  23. Disconnect all of the necessary vacuum lines, including the brake booster vacuum hose.
  24. Disconnect the fuel feed line at the fuel rail.

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  25. Disconnect the throttle cable from the throttle body and the intake manifold bracket.
  26. Disconnect the surge tank coolant hose at the throttle body.
  27. Disconnect the heater outlet hose at the coolant pipe.
  28. Disconnect the heater inlet hose from the cylinder head.
  29. Disconnect the surge tank coolant hose from the coolant pipe.
  30. Disconnect the lower radiator hose from the coolant pipe. Disconnect the starter solenoid "S" terminal wire. Remove the A/C compressor, if equipped. Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning Systems.

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  31. Remove the catalytic converter retaining nuts from the exhaust pipe.
  32. Remove the exhaust pipe.

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  33. Remove the crankshaft pulley bolt.
  34. Remove the crankshaft pulley.
  35. Disconnect the vacuum lines at the charcoal canister purge solenoid.
  36. Disconnect the electrical connector at the charcoal canister purge (CCP) solenoid and at the knock sensor.
  37. Disconnect the electrical connector at the oil pressure switch and at the exhaust gas recirculation (EGR) solenoid.
  38. Disconnect the crankshaft position sensor (CPS) connector.

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  39. Remove the transaxle torque converter bolts, if automatic transaxle equipped.
  40. Remove the stater motor. Refer to Section 1E, Engine Electrical.
  41. Remove the transaxle bell housing bolts.
  42. Support the transaxle with a floor jack.
  43. Install the engine lifting device.

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  44. Disconnect the right engine mount bracket from the engine mount and the engine by removing the attaching bolts and the nuts.
  45. Remove the right engine mount from the engine block. Refer to "Engine Mount" in this section.
  46. Separate the engine block from the transaxle.
  47. 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 right engine mount to the engine block. Refer to "Engine Mount" in this section.

  5. Connect the right engine mount bracket to the engine mount and the engine by installing the attaching bolts and the nuts.

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


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

    9. Tighten
    Tighten the transaxle torque converter bolts to 45 N•m (33 lb-ft).

  9. Install the starter motor. Refer to Section 1E, Engine Electrical.

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  10. Connect the vacuum lines at the CCP solenoid.
  11. Connect the electrical connector at the CCP solenoid and at the knock sensor.
  12. Connect the oil pressure switch and the EGR solenoid connectors.
  13. Install the crankshaft pulley.
  14. Install the crankshaft pulley bolt.

    15. Tighten
    Tighten the crankshaft pulley bolt to 95 N•m (70 lb-ft) and retighten 30 degrees plus 15 degrees.


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  15. Connect the CPS connector.
  16. Install the exhaust front pipe.
  17. Install the catalytic converter retaining nuts to the exhaust pipe.

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


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

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  21. Install the generator. Refer to Section 1E, Engine Electrical.
  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.

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  26. Connect all of the necessary vacuum lines, including the brake booster vacuum hose.
  27. Connect the O2 sensor connector, if equipped.
  28. Connect the starter solenoid "S" terminal wire and power lead.
  29. Connect the generator voltage regulator connector and power lead.
  30. Connect the CTS connector.
  31. Connect the MAP, MAT sensor connectors.
  32. Connect the TPS connector.
  33. Install the electrical wiring harness clamp at the intake manifold support bracket.

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  34. Connect the fuel injector harness connectors.
  35. Connect the electrical connector at the DIS coil and the ECM ground terminal at the starter.
  36. Install the air cleaner outlet hose between the throttle body and the air cleaner housing.
  37. Connect the breather tubes to the camshaft cover.
  38. Install the cooling system radiator and the engine cooling fans. Refer to Section 1D, Engine Cooling.

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  39. Connect the lower radiator hose to the coolant pipe.
  40. Connect the upper radiator hose to the thermostat housing.
  41. Connect the surge tank coolant hose to the radiator.
  42. Connect the heater inlet hose to the cylinder head.
  43. Connect the heater outlet hose to the coolant pipe.
  44. Connect the coolant surge tank hose to the coolant pipe.
  45. Connect the surge tank coolant hose to the throttle body.

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

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Pistons and Rods

Tools Required

KM-427 Piston Pin Service Set
KM 470-B Angular Torque Gauge

Removal Procedure

  1. Remove the cylinder head with the intake manifold and the 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.
  4. Remove the oil suction pipe.

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  5. Move the piston to the bottom of the piston stroke.
  6. Mark the connecting rod cap for position.
  7. Remove the connecting rod cap bolts.
  8. Remove the connecting rod cap and the lower connecting rod bearing.
  9. Remove the upper piston connecting rod bearing.
  10. 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.

  11. Remove the piston.
  12. Use a piston ring expander tool to expand the piston rings.
  13. Remove the piston rings.

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  14. Remove the piston pin from the piston and connecting rod assembly using the piston pin service set KM-427.
  15. 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 a bore gauge. 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

  1. Align the notch on the piston and the 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.
  5. Install the piston pin into the piston and connecting rod assembly using the piston pin service set KM-427.

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  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 a ring compressor 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 25 N•m (18 lb-ft). Using the angular torque gauge KM-470-B, tighten the bolts one turn of 30 degrees plus one turn of 15 degrees.


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

    23. Tighten
    Tighten the oil suction pipe bolts to 10 N•m (89 lb-in).

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


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