Engine Removal and Installation

REMOVAL





1. Disconnect battery cables.
2. Remove battery and battery tray.





3. Drain engine coolant.
4. Remove data link connector upward from mass airflow sensor bracket.
5. Disconnect intake air temperature sensor connector and mass air flow sensor connector.
6. Disconnect air intake hose from throttle body.
7. Disconnect ventilation hose.
8. Remove fresh air duct.





9. Remove accelerator cable and cruise control cable if equipped.
10. Remove air cleaner assembly.





11. Disconnect brake vacuum hose and purge control vacuum hose from dynamic chamber.
12. Remove upper and lower radiator hoses.





13. Disconnect fuel hose from fuel injector rail.

WARNING: Keep open flames and sparks away from open fuel lines or a fire or explosion may result.





14. Remove heater hoses.





15. Disconnect IAC and throttle position sensor connectors.





16. Disconnect injector connectors.





17. Disconnect electric connectors, bracket and reinstall engine hanger.

Tightening torque: 27.5 - 38.3 ft. lbs. (37.2 - 51.9 Nm, 3.8 - 5.3 kg-m)





18. Disconnect B-terminal connector and S-terminal connector from starter.





19. Disconnect generator B-terminal connector and connector C121 from generator.





20. Disconnect engine ground strap.





21. Remove RH & LH splash shield.





22. Remove exhaust manifold heat shield and three P/S pump bracket bolts.





23. Remove four A/C compressor bolts and five A/C compressor mounting bracket bolts.





24. Disconnect ground strap from top of transaxle.
25. Remove three No. 4 engine mounting nuts and one bolt and remove No. 4 engine mount.





26. Disconnect input/turbine speed sensor connector (A/T).
27. Disconnect back-up light switch connector(M/T).





28. Disconnect vehicle speed sensor connector.
29. Remove U-clip from selector cable to transaxle linkage (A/T).





30. Remove nut and washer from transaxle linkage (A/T).
31. Remove manual transaxle linkage and extension bar (M/T).





32. Remove clutch release cylinder and pipe (M/T).
33. Disconnect transaxle range switch connector (A/T).
34. Disconnect solenoid valve connector (A/T).





35. Disconnect two ATF cooler hoses (A/T).
36. Remove both front wheels (four lug nuts each).
37. Disconnect front oxygen sensor connector.





38. Remove front exhaust pipe.
39. Remove both right and left tie rod ends from steering knuckles by removing one cotter pin and one nut each.
40. Remove stabilizer control link bolt and nut from both right and left stabilizer control links then remove stabilizer control link.
41. Remove pinch bolt and nut from both right and left ball joints.





42. Separate ball joints from control arms.
43. Remove joint shaft support bracket from engine block (three bolts).





44. Gently pry both driveshafts from transaxle.





45. Support engine with engine hoist.





46. Remove two nuts from No. 2 engine mount-to-mounting member.
47. Remove one bolt from No. 3 engine mount.





48. Remove three No.1 engine mount bolts.
49. Lift engine and transaxle out as a unit.

INSTALLATION
1. Install engine and transaxle into engine compartment as a unit.





2. Install three No.1 engine mount bolts.

Tightening torque: 49.2 - 69 ft. lbs. (67 - 93.2 Nm, 6.8 - 9.5 kg-m)

3. Install No.3 engine mount bolt.

Tightening torque: 62.9 - 86 ft. lbs. (85.3 - 116.6 Nm, 8.7 - 11.9 kg-m)





4. Install two No.2 engine mount nuts.

Tightening torque: 28 - 38 ft. lbs. (38 - 51 Nm, 3.8 - 5.3 kg-m)





5. Install No.4 engine mount.

Tightening torque:
Nuts: 49 - 68 ft. lbs. (68 - 93 Nm, 6.8 - 9.5 kg-m)
Bolt: 47 - 66 ft. lbs. (64 - 89 Nm, 6.5 - 9.1 kg-m)

6. Remove engine hoist.
7. Install new clips on driveshaft.
8. Push driveshaft and joint shaft into transaxle with opening of clips pointing upward.
9. Install joint shaft support bracket using three bolts.

Tightening torque: 32 - 46 ft. lbs. (43 - 62 Nm, 4.4 - 6.3 kg-m)

10. Install right and left lower ball joints into spindle then install pinch bolts.

Tightening torque: 32 - 39 ft. lbs. (43 - 52 Nm, 4.4 - 5.3 kg-m)





11. Install both right and left stabilizer control links.

Tightening torque: 32 - 45 ft. lbs. (43 - 61 Nm, 4.4 - 6.2 kg-m)





12. Install front exhaust pipe.

Tightening torque:
A: 29.7 - 40.5 ft. lbs. (40.2 - 54.9 Nm, 4.1 - 5.6 kg-m)
B: 51 - 69 ft. lbs. (69 - 94 Nm, 6.9 - 9.4 kg-m)
C:15.2 - 20.2 ft. lbs. (20.6 - 27.4 Nm, 2.1 - 2.8 kg-m)





13. Connect two ATF cooler hoses (A/T).
14. Connect solenoid valve connector (A/T).
15. Connect auto transaxle range switch connector (Air).





16. Install clutch release cylinder and pipe (M/T).

Tightening torque: 13.7 - 18.8 ft. lbs. (18.6 - 25.5 Nm, 1.9 - 2.6 kg-m)

17. Install extension bar and manual transaxle linkage.

Extension bar tightening torque: 23 - 34 ft. lbs. (32 - 47 Nm)
Manual transaxle linkage tightening torque: 12 - 17 ft. lbs. (16 - 23 Nm)

18. Install washer and nut to auto transaxle linkage (A/T).

Tightening torque: 24 - 83 ft. lbs. (32 - 46 Nm, 3.2 - 4.7 kg-m)





19. Insert U-clip.
20. Connect back-up light switch connector (M/T).





21. Connect vehicle speed sensor connector (M/T).





22. Connect input turbine speed sensor connector.





23. Connect ground strap to top of transaxle.





24. Install A/C compressor mounting bracket (five bolts)

Tightening torque:
Mounting bracket:
Four: (14mm) bolts: 28 - 38 ft. lbs. (38 - 51 Nm, 3.9 - 5.2 kg-m)
One: (12mm) bolt (oil pump side): 14 - 18 ft. lbs. (19 - 25 Nm, 1.9 - 25 kg-m)
A/C compressor: 28 - 38 ft. lbs. (39 - 52 Nm, 3.9 - 5.3 kg-m)

25. Install three P/S pump bracket bolts.

Tightening torque: 28 - 38 ft. lbs. (39 - 52 Nm, 3.9 - 5.3 kg-m)





26. Install exhaust manifold heat shield.

Tightening torque: 13.7 - 22.4 ft. lbs. (18.6 - 30.4 Nm, 1.9 - 3.1 kg-m)





27. Install RH & LH splash shield.

Tightening torque: 10 - 12 ft. lbs. (13.5 - 16 Nm, 1.4 - 1.6 kg-m)

28. Install both front wheels.

Tightening torque: 65 - 87 ft. lbs. (88 - 118 Nm, 9 - 12 kg-m)





29. Connect engine ground strap.

Tightening torque:
A: 28 - 38 ft. lbs. (38 - 51 Nm, 3.8 - 5.3 kg-m)
B: 5.8 - 8.7 ft. lbs. (7.8 - 11.8 Nm, 0.8 - 1.2 kg-m)





30. Connect two generator connectors. (B-terminal connector and C121 to the generator)





31. Connect B-terminal and S-terminal connectors to the starter.





32. Connect IAC and throttle position sensor connectors.





33. Install connector bracket and connect electric connectors.

Tightening torque: 27.5 - 38.3 ft. lbs. (37.2 - 51.9 Nm, 3.8 - 5.3 kg-m)





34. Connect injector connectors.





35. Connect heater hoses.





36. Connect fuel hose to injector rail.





37. Connect upper and lower radiator hoses.





38. Connect brake vacuum hose and purge control vacuum hose to dynamic chamber.
39. Install air cleaner assembly and connect air intake hose to throttle body.
40. Install fresh air duct.
41. Connect ventilation hose.
42. Install accelerator cable and auto cruise control cable, if equipped.
43. Insert data link connector into mass air flow sensor bracket.





44. Connect intake air temperature sensor connector and mass air flow sensor connectors.





45. Install P/S and A/C belt. Turn adjustment screw until correct belt deflection is achieved. Tighten pivot bolt and mounting bolt.

Deflection:
New: 8.0 - 9.0 mm (0.32 - 0.35 inch)
Vised: 9.0 - 10.0 mm (0.36 - 0.39 inch)

46. Install battery tray and battery.

Tightening torque: 10 - 12 ft. lbs. (13.5 - 16 Nm, 1.4 - 1.6 kg-m)

47. Fill engine coolant with specified type and amount.
48. Connect both battery cables.
49. Check and/or fill all fluids.
50. Test run engine and perform an overall check.