Engine: Service and Repair
REMOVAL / INSTALLATIONNote: Make sure jacks and safety stands are placed properly and hoist brackets are attached to correct positions on the engine. Use fender covers to avoid damaging painted surfaces.
1. Disconnect battery negative terminal first, then positive terminal.
Note: On reassembly, clean battery posts and cable terminals with sandpaper, assemble, then apply grease to prevent corrosion.
2. Remove the front bumper apron, then the grille.
3. Unbolt the hood bracket and remove the hood.
4. Drain engine oil. Remove oil filler cap to speed draining. Reinstall drain plug with new washer.
Note: Do not re-use old washer.
5. Drain coolant from radiator and engine block into a clean pan so it may be re-used. Remove radiator cap to speed draining.
Note: Use care when removing radiator cap to avoid scalding by hot coolant or steam.
Note: On installation, apply sealant to the drain plug.
6. Drain transmission oil/fluid. Use a 3/8" drive socket wrench to remove drain plug. Remove oil filler plug to speed draining. Reinstall drain plug with new washer.
7. Disconnect air intake duct and hot air duct.
8. Remove air cleaner cover and filter.
9. Remove screw holding condensation chamber. Remove three nuts holding vacuum hose supports. Remove two nuts and bolts holding air cleaner. Remove screw holding external resistor.
10. Lift air cleaner up and disconnect intake air temperature sensor control tube. Disconnect coupler to air temperature sensor, then remove air cleaner.
11. Disconnect the brake booster vacuum hose from brake booster.
12. Disconnect the wires above:
Note: On reassembly - connect all wires properly; checking that they are not pinched or interfering with adjacent parts.
13. Disconnect fuel hose at the fuel filter.
14. On cars with A/C, remove idle control solenoid valve.
15. Remove throttle cable by loosening locknut and throttle cable adjusting nut, then slip cable end out of throttle bracket and carburetor linkage.
Note: Take care not to bend cables when removing them. Do not use pliers to remove cables from linkage. Replace kinked cable with new one.
16. Remove anti-tampering band and disconnect control box connector. Lift control box oft its bracket, and let it hang next to engine.
17. Disconnect purge control solenoid valve vacuum hose at charcoal canister.
18. CALIFORNIA/HIGH ALTITUDE MODELS Only:
- Remove air jet controller.
19. Disconnect charcoal canister hoses to the carburetor.
20. Pull the window washer reserve tank away from the harness connector bracket. Disconnect both engine harness connectors.
21. On 4-door models:
- Remove the cruise control actuator bracket bolts (2), disconnect the vacuum hose and electrical connector. Then pull the actuator away from the body panel. Disconnect the vacuum reservoir hose.
22. Disconnect radiator hoses and heater hoses at engine.
Note: Disconnect heater hose with water valve cable attached. On reassembly, do not interchange inlet and outlet hoses.
Note: When refilling cooling system, open heater valve and unscrew air bleed bolt to bleed air out of system.
23. On Automatic Cars:
Disconnect transmission oil cooler hoses at the transmission, let ATF drain from hoses, then hang hoses up out of the way near the radiator.
Disconnect engine oil cooler hoses from cooler, let oil drain, then cap hose ends with suitable plugs and hang hoses on engine.
Note: On installation, DO NOT interchange inlet and outlet hoses.
24. On Manual Cars:
- Loosen clutch cable adjusting nut and disconnect clutch cable from release arm.
Note: After installing engine, readjust clutch pedal free play.
- Remove cable clip, then pull the speedometer cable out of holder.
Note: Do not remove holder because speedometer gear may fall into transmission housing.
During Installation:
- Align tab on cable end with slot in holder.
- Install clip so bent leg is on groove side.
- After installing, pull speedometer cable to make sure it is secure.
25. Remove anti-afterburn valve.
Note: Anti-afterburn valve is adjacent to engine hoist bracket and may be damaged during engine removal if not removed.
26. On Cars with Power Steering:
- Remove speed sensor complete with hoses.
Note: If you disconnect the hoses from the speed sensor, power steering fluid will flow out.
Remove adjusting bolt and V-belt.
- Without disconnecting hoses, remove the pump from its mounting bracket.
27. On Cars with A/C:
- Remove compressor belt cover, then loosen belt adjusting bolt.
- Remove clamp on compressor hose bracket at radiator.
- Remove compressor mounting bolts, then lift compressor out of bracket, with hoses attached, and wire it up to front bulkhead.
Note: Compressor can be moved without discharging air conditioner system.
- Remove compressor bracket (6 bolts).
28. Manual Transmission Only:
- Remove shift rod yoke attaching bolt.
Note: Shift to 1st to ease bolt removal
- Disconnect shift lever torque rod from clutch housing.
29. Automatic Transmission Only:
- Remove center console.
- Place shift lever in reverse, then remove lock pin from end of shift cable.
Note: On reassembly, check cable adjustment.
- Unscrew cable mounting bolts and remove shift cable holder.
- Remove throttle control cable in numbered sequence.
30. Loosen front wheel nuts slightly and jack up front of car. Place safety stands under frame at proper positions and remove front wheels.
- Apply parking brake and block rear wheels so car will not roll off stands and fall on you while working under it.
31. Remove cotter pin from tie-rod end and remove castle nut.
- Disconnect right and left lower arm bolts and tie-rod end ball joints using ball joint removal tool.
32. Turn right steering knuckle outward as far as it will go. With screwdriver against inboard CV joint, pry right axle out of transmission housing approximately 1/2 inch (to force its spring clip out of groove inside differential gear splines), then pull it out the rest of the way. Repeat on opposite side.
Note: Do not damage differential seals.
Note: When installing drive shaft, insert shaft until spring clip "clicks" into groove in differential side gear.
Note: Always use new spring clips when installing driveshafts.
33. Disconnect exhaust header pipe at manifold.
Note: To ease disassembly, squirt penetrating oil on exhaust manifold studs before removing nuts.
- Replace exhaust gasket and self-locking nuts on reassembly.
34. Attach hoist chain to engine block and raise hoist just enough to remove slack from chain with slight tension.
35. Remove three engine mount bolts.
Note: On cars with A/C the two 8 mm bolts were already removed in step 27.
36. Then push engine mount into the engine mount tower.
37. Remove front engine mount nut.
38. Remove rear engine mount nut.
39. Remove bolt from rear torque rod at engine. Then loosen bolt in frame mount and swing rod up out of the way.
Note: It will be necessary to raise the charcoal canister to remove the frame mount bolt.
40. Check that engine/transaxle is completely free of vacuum, fuel, and coolant hoses; and electrical wires.
41. Slowly raise engine approximately 6" and stop. Check once again that all wires and hoses have been disconnected from engine/transaxle.
42. Raise engine all the way and remove from car.
Note: Coat all precision finished surfaces with clean engine oil or grease. Tie plastic bags over the drive shaft ends.
43. Install engine in reverse order of removal. After engine is in place.
- Torque engine mount bolts in sequence shown.
Note: Failure to tighten bolts in proper sequence could cause excessive noise and vibration, and reduce bushing life; check that bushings are not twisted or offset.
- Check that spring clip on end of each driveshaft clicks into differential.
Note: Use new spring clips on installation.
- Bleed air from cooling system at bleed bolt with heater valve open.
- Adjust throttle cable tension.
- Check clutch pedal free play.
- Check that transmission shifts into gear smoothly.
- Connect air conditioning hoses and wiring.