Engine: Service and Repair
REMOVAL1. Remove the battery.
2. Detach the air cleaner.
3. Disconnect the connectors for the backup lamp switch and engine harness.
4. For a vehicle with a 5-speed manual transaxle, disconnect the select control valve connector.
5. Disconnect the connectors for the generator harness and the oil pressure gauge wiring.
6. Drain the engine coolant.
7. For vehicles with an automatic transaxle, disconnect the transaxle oil cooler hoses.
NOTE: When disconnecting the hoses, identify their location to avoid making any errors during reassembly.
CAUTION: Be careful not to spill any oil or fluids. Also take care in preventing the entrance of foreign material.
8. Disconnect the radiator upper and lower hoses on the engine side, and then remove the radiator assembly.
9. Disconnect the engine ground.
10. Disconnect the brake booster vacuum hose.
11. Remove the main fuel line, and the return and vapor hoses from the engine side.
CAUTION: To reduce the residual pressure in the hoses, refer to Powertrain Management; Fuel Delivery and Air Induction.
12. Disconnect the heater hoses (inlet and outlet) on the engine side.
13. Disconnect the accelerator cable at the engine side.
14. For vehicles with a manual transaxle, remove the clutch cable from the transaxle.
15. For vehicles with an automatic transaxle, remove the control cable from the transaxle.
16. Disconnect the speedometer cable from the transaxle.
17. Disconnect the air conditioning compressor.
18. Jack up the vehicle.
19. Drain the transaxle oil (or fluid).
20. Disconnect the front exhaust pipe from the manifold.
NOTE: Use wire to suspend the exhaust pipe from the bottom of the vehicle.
21. For vehicles with a manual transaxle, remove the shift control rod and extension rod.
22. Remove the lower arm ball joint bolts and the strut bar at the point where it is mounted to the lower arm.
23. Remove the drive shafts from the transaxle case.
CAUTION:
1. Plug the axle holes of the transaxle case to prevent entry of foreign material.
2. Install new circlips on the drive shafts when reassembling.
24. Hang the lower arm and drive shaft from the body with wire.
25. Attach a cable to the engine, and use a chain hoist to lift the engine only enough to pull the cable tight.
26. Remove the front roll stopper.
27. Separate the rear roll stopper.
28. For vehicle with a manual transaxle, remove the roll rod.
29. Remove the engine mounting insulator bolts.
30. Remove the engine mounting bracket from the engine.
31. Slowly raise the engine (to the extent that the engine and transaxle weights are not applied to the mounting portions) and temporarily hold it in the raised condition.
CAUTION: Check that all of the cables, hoses, harnesses, connectors etc. are disconnected from the engine.
32. Remove the caps from inside the right fender shield and remove the transaxle mount bracket bolts.
33. Remove the engine mount insulator bolt. While directing the transaxle side downward, lift the engine and transaxle assembly up and out of the vehicles.
INSTALLATION
1. After checking the connections of the harness, pipes, hoses, etc., and making sure that name of them are being caught, damaged etc., install the engine and transaxle assembly.
2. Install the mounting stoppers with the arrows on them pointing in the direction as shown.
3. When the engine and transaxle assembly is in place, temporarily tighten the front roll stopper.
4. The front and rear rubber bushings and collars of the center member support are different.
5. After the weight of the engine and transaxle assembly has been put on each insulator, tighten them to the specified torque.
6. Reassembly all of the components removed during disassembly. Be especially careful to properly secure all components, including fuel, electrical and fluid pipe connections.
7. Refill the coolant and check for leaks.
8. Refill the transaxle fluid, test its operation, and check for leaks.
9. Check the operation of the transaxle control cable and accelerator cable. Adjust if necessary.
10. Check for proper operation of each of the various gauges.