Engine: Service and Repair

ENGINE AND TRANSAXLE ASSEMBLY REMOVAL
1. Remove the battery.
2. Detach the air cleaner.
3. Disconnect the connectors for the backup lamp 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, make identification marks to avoid making any mistakes in reconnecting them.

CAUTION:
Be camful not to spill oil or fluid out of the hoses, and plug the openings to prevent the entrance of foreign material.

8. Disconnect the radiator upper and lower hoses on the engine side.






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:
Reduce the residual pressure in the hoses.






12. Disconnect the heater hoses (inlet end 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. For vehicles with manual transaxle, remove the shift control rod and extension rod.






17. Disconnect the connector of the vehicle speed sensor from the transaxle.






18. Separate the column shaft from the steering gear box.






19. Remove the engine mounting insulator.






20. Remove the transaxle mounting insulator.






21. After removing the wheel and attaching the wheel speed sensor and caliper to the body, disconnect the lower arm and the fork, and then separate the upper arm and knuckle.






22. Jack up the vehicle.
23. Drain the transaxle oil (or fluid).
24. Disconnect the front exhaust pipe from the manifold.

NOTE:
Use wire to suspend the exhaust pipe from the bottom of the vehicle.






25. Place the supporter under the sub-frame.

CAUTION:
Check that all of the cables, hoses, harnesses, connectors etc are disconnected from the engine.






26. To remove the sub-frame, engine, transaxle, steering gear box end drive shaft all together. Loosen the subframe bolts (6 each) and slowly lift the vehicle with the hoist.
27. Remove the driver shaft and hang the engine and transaxle at the hoist, then separate engine and transaxle from the subframe.






To separate the engine and transaxle from the sub-frame remove the Engine mounting bracket and Transaxle mounting bracket, and then raise the hoist.

INSTALLATION
1. While checking the connections of the harnesses. pipes, hoses. etc., make sure that none of them is being caught, damaged, etc.






2. To place the engine and transaxle assembly on the sub-frame install the front roll stopper and rear roll stopper among the sub-frame and engine, transaxle assembly.

NOTE:
Especially, when installing front rail stopper mounting bracket, be careful not to crush the insulator, If crushed, idle vibration will be excessive.

3. To install the engine transaxle and sub-frame follow the removal procedures in the reverse order.
4. Refill the coolant and check for leak.
5. Refill the transaxle fluid, test its operation, and check for leak.
6. Check for the operation of the transaxle control cable and accelerator cable. Adjust as necessary.
7. Check for proper operation of each of the various gauges.