Engine: Service and Repair

1. Disconnect battery ground cable.
2. Mark hood hinge area and remove hood.
3. Remove grille attaching screws, then the grille.
4. Remove radiator support attaching screws, face panel, support and panel assembly.
5. On models equipped with air conditioning, slowly and carefully discharge refrigerant from system.
6. Disconnect radiator lower hose and drain coolant from radiator. Drain coolant into a suitable container.
7. Disconnect upper radiator hose.
8. Disconnect heater hoses at the heater core.
9. Disconnect coil, alternator and starter electrical connectors and cables.
10. Remove engine ground straps.
11. Label, then disconnect all vacuum hoses.
12. Disconnect fuel supply and return lines from fuel rail.
13. Disconnect accelerator cable from throttle plate and valve cover.
14. Disconnect throttle plate cover hoses.
15. On models equipped with manual transaxle, disconnect clutch cable from bracket and release lever on the clutch housing.
16. Remove ignition TDC sensor from clutch or converter housing.
17. Disconnect and remove ECU top cover as follows:
a. Remove plastic screw from cover mounting stud.
b. Disconnect electrical connector.
c. Loosen upper and lower attaching clips, then place ECU top cover and electrical connectors/wires aside on the engine.
18. Remove air cleaner assembly.
19. Disconnect cooling fan and thermo switch electrical connectors.
20. Remove exhaust head pipe to exhaust manifold attaching bolts.
21. Raise and support vehicle.
22. Remove underbody splash shield attaching bolts, then the splash shield.
23. On models equipped with automatic transaxle, cut tie straps securing BVA module wires to the engine harness. Disconnect module and position aside.
24. Loosen and remove power steering drive belt. Remove pump attaching bolts and position pump assembly aside.
25. Remove exhaust head pipe mounting bolt. Remove two spring loaded attaching bolts connecting head pipe to converter pipe. Separate converter pipe from head pipe.
26. Remove radiator cooling fan.
27. On models equipped with A/C, remove radiator, condenser and cooling fan as an assembly.
28. On models equipped with automatic transaxle, remove starter motor. Mark position of torque converter and flex plate for assembly. Remove converter attaching bolts working through starter opening.
29. Remove engine to transaxle bellhousing attaching bolts, then lower vehicle.
30. Remove as follows:
a. Attach a suitable chain to engine and engine hoist.
b. Attach one end of chain to engine lifting eye.
c. Wrap other end of chain around coolant outlet housing located at the front of the engine. If it appears that the lifting chain may contact either of the housing sensors, remove the sensors before lifting the engine.
d. Remove nuts attaching engine mount cushions to engine cradle.
e. Raise engine off cradle and pull it forward until clear of transaxle assembly.
f. Lift engine assembly up and out of engine compartment at approximately a 15° angle.
g. Position suitable supports under the transaxle immediately after removing the engine. Do not allow transaxle the remain unsupported.
31. Reverse procedure to install.