Engine Removal and Installation

REMOVAL PROCEDURE

^ Tools Required
- J 28467-A Universal Support Fixture
- J 28467-89 Engine Support Fixture Adaptors (Metro)
- J 36295 Engine/Transmission Frame Handler

IMPORTANT: The engine/transaxle assembly is removed from the underside of the vehicle.

1. Relieve the fuel pressure.
2. Remove the negative and the positive battery cables from the battery.
3. Remove the hood assembly.
4. Drain the cooling system.
5. Remove the radiator with the cooling fan.
6. Remove the air cleaner assembly.
7. Discharge the Air Conditioning (A/C) system.

IMPORTANT: All components below are in one wiring harness.

8. Disconnect the following electrical connections:
^ The coolant temperature gauge sensor connector The throttle position sensor connector The purge solenoid valve connector The camshaft position (CMP) sensor connector
^ The throttle position sensor connector
^ The purge solenoid valve connector
^ The camshaft position (CMP) sensor ground wire
^ The crankshaft position (CKP) sensor connector
^ The Idle Speed Control (ISC) solenoid valve connector
^ The oxygen sensor connector (HO2S1)
^ The oxygen sensor connector (HO2S2) The four fuel injector connectors The Manifold Absolute Pressure (MAP) sensor connector The power steering (P/S) pump pressure switch (if equipped) The oil pressure switch connector The A/C compressor clutch connector The park/neutral position (PNP) switch connector
^ The ground wire connector from the intake manifold
^ The ignition coil connectors
^ The generator connectors
^ The generator B+
^ The starter solenoid connector
^ The positive battery cable from the starter solenoid
^ The backup lamp switch (manual transaxle)
^ The vehicle speed sensor connector
^ Position the negative battery cable on top of the transaxle
^ The direct clutch and the second brake solenoid connector

9. Release the harness from the clamps and position the harness aside.
10. Remove the lower chorister purge hose from the purge solenoid valve and position aside.
11. Remove the brake booster hose from the intake manifold.
12. Remove the following cables:
^ The accelerator cable from the throttle body and the intake manifold
^ The clutch cable from the transaxle (manual transaxle equipped vehicles)
^ The shift select cable from the transaxle (automatic transaxle equipped vehicles)
^ The TV cable from the transaxle (automatic transaxle equipped vehicles)
^ The speedometer cable from the transaxle

13. Remove the inlet and outlet hoses from the heater core.
14. Remove the fuel feed and return hoses at the fuel rail.
15. Install the J28467-A with the J 28467-89
16. Remove the rear engine mount.
17. Remove the right side engine mount.
18. Remove the left transaxle mount.
19. Raise and support the vehicle.
20. Drain the engine oil.
21. Drain the transaxle fluid.
22. Remove the two nuts and the front pipe/catalytic converter assembly from the resonator/center pipe.
23. Remove the two bolts and the front pipe/catalytic converter assembly from the exhaust manifold.
24. Remove the hanger supporting the catalytic converter
25. Remove the front pipe/catalytic converter assembly from the vehicle.
26. Remove the following components from the transaxle (manual transaxle equipped vehicles):
^ The Gearshift shaft.
^ The extension rod.
27. Remove the torque rod (automatic transaxle equipped vehicles).

IMPORTANT: For engine/transaxle removal, it is not necessary to remove the wheel drive shaft from the steering knuckle.

28. Remove the left and right wheel drive shafts from the transaxle.
29. Remove the A/C compressor.
30. Remove the power steering pump (if equipped).
31. Lower the vehicle carefully until it rests on the J 36295
32. Remove the J 28467-A and the J 28467-89.

IMPORTANT: Ensure sufficient clearance on all sides for removal of the engine/transaxle assembly.

33. Raise the vehicle leaving the engine/transaxle assembly on the table.
34. Separate the engine from the transaxle.

INSTALLATION PROCEDURE

^ Tools Required
- J28467-A Universal Support Fixture
- 128467-89 Engine Support Fixture Adaptors (Metro)
J 36295 Engine/Transmission Frame Handler

1. Install the engine to the transaxle.

IMPORTANT: Ensure sufficient clearance on all sides for fitting the engine/transaxle assembly into the engine compartment.

2. Lower the vehicle onto the engine/transaxle assembly.
3. Install the J 28467-A J 28467-89.
4. Install the left transaxle mount.
5. Install the right side engine mount.
6. Install the rear engine mount.
7. Raise the vehicle.
8. Install the power steering pump (if equipped).
9. Install the Air conditioning (A/C) compressor to the compressor bracket.
10. Install the left and right drive axles to the transaxle.
11. Install the torque rod.
12. Install the Gearshift control shaft and the extension rod to the transaxle (manual transaxle equipped vehicles).
13. Install the front pipe/catalytic converter assembly to the vehicle. Support the catalytic converter with the hanger.
14. Install the front pipe/catalytic converter assembly to the resonator/center pipe; secure with two nuts. Do not fully tighten.
15. Install the front pipe/catalytic converter assembly to the exhaust manifold and secure with two bolts.
^ Tighten the exhaust manifold-to-front pipe catalytic converter bolts to 50 Nm (37 ft. lbs.).
^ Tighten the resonator/muffler/tail pipe-to-front pipe/catalytic converter nuts to 35 Nm (26 ft. lbs.).

16. Lower the vehicle.
17. Remove the J28467-A and the J28467-89.
18. Install the fuel feed and return hoses to the fuel rail.
19. Install the heater inlet and the heater outlet hoses to the heater core.
20. Install the following cables:
^ The accelerator cable to the throttle body and the intake manifold
^ The clutch cable to the transaxle (manual transaxle equipped vehicles)
^ The shift select cable to the transaxle (automatic transaxle equipped vehicles)
^ The TV cable to the transaxle (automatic transaxle equipped vehicles)
^ The speedometer cable to the transaxle

21. Install the lower canister purge hose to the purge solenoid valve.
22. Install the brake booster hose to the intake manifold.
23. Evacuate and recharge the A/C system.
24. Route the harness and secure the harness in the clamps.

IMPORTANT: All of the components below are in one wiring harness.

25. Connect the following electrical connections:
^ The coolant temperature gauge sensor connector
^ The throttle position sensor connector
^ The purge solenoid valve connector
^ The camshaft position (CMP) sensor connector
^ The camshaft position (CMP) sensor ground wire
^ The crankshaft position (CKP) sensor connector
^ The Idle Speed Control (ISC) solenoid valve connector
^ The oxygen sensor connector (HO2S1)
^ The oxygen sensor connector (HO2S2)
^ The four fuel injector connectors
^ The Manifold Absolute Pressure (MAP) sensor connector
^ The power steering (P/S) pump pressure switch (if equipped)
^ The oil pressure switch connector
^ The A/C compressor clutch connector
^ The park/neutral position (PNP) switch connector
^ The ground wire connector from the intake manifold
^ The ignition coil connectors
^ The generator connectors
^ The generator B+ wire
^ The starter solenoid connector
^ The positive battery cable to the starter solenoid
^ The backup lamp switch (manual transaxle)
^ The vehicle speed sensor connector
^ Route the negative battery cable
^ The direct clutch a solenoid connector

26. Install the radiator wit the cooling fan.
27. Fill the cooling system.
28. Install the air cleaner assembly.
29. Fill transaxle as necessary.
30. Fill the engine with and Oil Filter Replacer
31. Adjust the clutch pedal free travel (manual transaxle equipped vehicle).
32. Adjust the shift select cable (automatic transaxle equipped vehicles).
33. Adjust the TV cable (automatic transaxle equipped vehicles).
34. Adjust the accelerator cable free play
35. Install the hood assembly.
36. Install the positive and the negative battery cables to the battery.
37. Inspect the vehicle for the following conditions:
^ Fuel leaks
^ Water leaks
^ Exhaust gas leak

38. Run the engine and pressure.