Engine: Service and Repair

1. Disconnect battery ground cable, then positive cable.
2. Remove hood, then drain engine oil, cooling system and transaxle.
3. Remove battery and battery tray.
4. On models with carbureted engine, proceed as follows:
a. Remove air intake hose and air cleaner.
b. Disconnect fuel line at fuel filter, then disconnect power brake vacuum hose at one way valve.
c. Remove air jet controller attaching bolts and position aside with hoses attached.
5. On models with fuel injected engine, proceed as follows:
a. Disconnect air intake hose and resonator hose.
b. Remove battery wire from relay box.
c. Slowly loosen service bolt on fuel filter approximately one turn to relieve fuel system pressure. Place shop towel around fuel filter to prevent fuel spray and allow fuel to drain into a suitable container.
d. Disconnect fuel pressure and return hoses.
6. On all models, disconnect evaporate emission control hose at throttle body or carburetor.
7. Disconnect accelerator cable at throttle body or carburetor.
8. Disconnect electrical connectors and ignition wires, then remove distributor.
9. Disconnect radiator and heater hoses from engine.
10. On models with automatic transaxle, disconnect oil cooler lines.
11. On models equipped with cruise control, disconnect vacuum hose, then remove actuator.
12. On fuel injected engine, proceed as follows:
a. Disconnect engine wiring harness connectors from right-hand engine compartment wiring harness.
b. Disconnect two electrical connectors, then remove emission control box and vacuum tank with vacuum hoses connected.
c. Disconnect power brake unit vacuum hose at intake manifold chamber.
13. On all models, remove power steering pump from mounting bracket, then disconnect inlet hose and position power steering pump aside. Position shop towel over alternator when disconnecting power steering pump inlet hose.
14. Remove alternator.
15. On models with A/C, proceed as follows:
a. Remove condenser fan shroud.
b. Remove A/C compressor from mounting bracket, then using wire, suspend from frame with refrigerant hoses attached.
16. On models with manual transaxle, disconnect shift and select cables from transaxle, then remove cable bracket.
17. On models with automatic transaxle, disconnect shift control cable at transaxle.
18. On all models, disconnect ground wire at transaxle.
19. Remove both front driveshafts, refer to Transmission and Drivetrain/Drive Axles, Bearings and Joints section for procedure.
20. On models with manual transaxle, remove clutch slave cylinder attaching bolts, then position slave cylinder aside with hose attached.
21. On all models, remove speed sensor and speedometer cable.
22. Support engine using a suitable engine lifting fixture.
23. Remove rear engine mount bolt, then remove bracket.
24. Remove front engine mount bolt, side engine mount bolts and transaxle mount bolt.
25. Check to ensure all linkages, wiring, hoses and lines are disconnected to permit engine and transaxle removal.
26. Tilt engine slightly, then carefully remove engine and transaxle assembly from vehicle.

Fig. 5 Engine Mount Tightening Sequence:

27. Reverse procedure to install, noting the following:
a. Refer to Fig. 5 for engine mount torque specifications.
b. When installing driveshafts, use new spring clips and ensure driveshafts click into groove into differential.
c. After refilling cooling system, loosen bleed bolt and start engine. Tighten bleed bolt when cooling system trapped air has escaped and coolant begins to flow.
d. Adjust all control cables as required.