Engine: Service and Repair

Fig. 2 Engine Removal & Installation:

Refer to Fig. 2, when replacing engine. Engine and transaxle should be removed as an assembly.
1. Relieve fuel system pressure as follows:
a. Loosen gas cap to release tank pressure.
b. Disconnect electrical connector from injector.
c. Ground one injector terminal using a jumper wire.
d. Connect jumper wire to second terminal and touch battery positive terminal for no longer than 10 seconds, then remove jumper wire.
2. Scribe hood hinge locations and remove hood.
3. Drain engine coolant, engine oil, and transaxle oil.
4. On manual transaxle models, drain clutch hydraulic fluid.
5. On all models, if equipped with air conditioning, discharge refrigerant.
6. Tape and isolate battery ground cable terminal. Wait at least 30 seconds before proceeding.
7. On all models, disconnect and remove battery, then battery tray, from vehicle.
8. Remove air cleaner assembly.
9. Disconnect electrical wiring and electrical sensors that would inhibit engine removal.
10. Disconnect purge hose and brake booster.
11. Disconnect accelerator cable, cable bracket, and cruise control cable.
12. Disconnect idle switch, motor position sensor vacuum hose, and fuel hoses.
13. On models equipped with manual transaxles, perform the following:
a. Disconnect transaxle control cables and remove the control cable bracket.
b. Remove air compressor.
c. Remove bracket connection.
d. Remove clutch release cylinder.
e. Disconnect speedometer cable.
14. On models equipped with automatic transaxles, perform the following:
a. Disconnect transaxle control cable.
b. Remove air compressor.
c. Disconnect speedometer cable, then disconnect transaxle oil cooler hoses at transaxle.
15. On all models, disconnect heater hoses.
16. Disconnect air conditioner hoses and connectors.
17. Remove high tension cable.
18. Disconnect power steering hoses.
19. Disconnect radiator upper and lower hoses and overflow tube, then disconnect electrical fan motor.
20. On models equipped with automatic transaxles, remove oil cooler hose and tube assemblies.
21. On all models, remove radiator and bushings.
22. Remove undercover panel.
23. Remove stabilizer bar mounting nut, then disconnect tie rod end.
24. Disconnect lower arm ball joint, then remove the lefthand side driveshaft.
25. Remove circlip, cotter pin, and driveshaft nut, then remove righthand side driveshaft.
26. Disconnect exhaust pipe.
27. Remove front and rear roll stopper bracket bolts.
28. Remove engine damper, engine mount bracket, and transaxle mount brackets.
29. Remove engine and transaxle assembly.
30. Separate engine and transaxle as follows:
a. Remove starter motor.
b. On models with automatic transaxle, remove bolts attaching driveplate to torque converter.
c. On all models, remove transaxle to engine attaching bolts, then separate transaxle from engine.
31. Reverse procedure to install, noting the following:
a. Tighten starter motor bolts to specifications.
b. On models with automatic transaxle, tighten driveplate to torque converter bolts to specifications.
c. On all models, tighten automatic transaxle to engine bolts to specifications.
d. On models with manual transaxle, tighten transaxle to engine bolts to specifications.
e. Refer to Fig. 2, for bolt tighten specifications.