Engine: Service and Repair

Engine and transaxle are removed as an assembly.
1. Disconnect battery ground cables.
2. Mark hood hinge locations, then remove hood.
3. Drain cooling system and discharge A/C system.
4. Remove air cleaner assembly.
5. Remove vacuum valve assembly from righthand shock tower.
6. Disconnect fuel lines and position aside.
7. Relieve fuel pressure as follows:
a. Start engine.
b. Disconnect fuel pump relay.
c. After engine stalls, turn ignition switch Off.
d. Reconnect fuel pump relay.
8. Remove upper radiator hose.
9. Disconnect all electrical connectors and looms and position aside.
10. Disconnect or remove the following:
a. Alternator.
b. A/C compressor clutch.
c. Ignition coil.
d. Engine coolant temperature sensor.
e. Injector wiring harness including six injector connectors.
f. Air charge temperature sensor and throttle position sensor.
g. Oil pressure sending switch.
h. Engine ground straps.
i. Block heater (if equipped).
j. Knock sensor and EGR sensor.
k. Oil lever sensor.
l. Vacuum lines, crankcase ventilation hoses.
m. Heater hoses and power steering pump return lines.
11. Disconnect A/C lines from condenser and chassis, leaving manifold lines attached to compressor.
12. Disconnect accelerator linkage, transmission throttle valve linkage and speed control cable (if equipped).
13. Remove battery and tray.
14. Remove fuse box and position aside.
15. Disconnect speed control servo and position aside.
16. On models with automatic transaxle, disconnect shift cable and electrical connectors and position aside.
17. On models with analog cluster, disconnect speedometer.
18. On models with electronic cluster, disconnect vehicle speed sensor connector.
19. On models with manual transaxle, remove clutch release cylinder with hose still attached and position aside.
20. On all models, remove radiator, cooling fan and shroud.
21. Raise and support vehicle.
22. Remove wheels and tires assemblies.
23. Remove lower radiator hose and front exhaust pipe.
24. Remove starter motor.
25. On models with automatic transaxle, remove torque converter nuts.
26. On models with manual transmission, remove shift control rod and extension bar.
27. On all models, remove stabilizer links and tie rod ends from lower control arms.
28. Disconnect lower ball joints, then pull down on control arms to disengage them from spindle.
29. Remove three bolts from dynamic damper bracket on righthand halfshaft assembly. Pulling outward on righthand brake and spindle assembly, disengage right halfshaft from transaxle.
30. Pulling outward on left hand brake and spindle assembly, disengage left halfshaft assemblies.

Fig. 2 Transaxle Plug Location:

31. Install two transaxle plugs T88C-7025-AH or equivalent into differential side gears. Failure to install transaxle plugs may allow differential side gears to become mispositioned, Fig. 2.

Fig. 1 Engine Mounts:

32. Disconnect lower rear transmission mount.

Fig. 3 Engine Removal:

33. Lower vehicle and attach a suitable lifting device, Fig. 3.
34. Disconnect lower front engine mount and righthand upper engine mount at timing cover.
35. Disconnect lefthand upper engine mount at transaxle case.
36. Carefully lift engine and transaxle assembly from vehicle.
37. Reverse procedure to install.