Pages 21-10-4, 21-10-5 & 21-10-5A

1986-89
21-10-4 Engine, 2.5L 21-10-4


REMOVAL AND INSTALLATION (Continued)

19. Remove air cleaner-to-canister hose.

20. Raise vehicle on hoist.

21. Drain engine oil.

22. Remove engine oil filter.

23. Disconnect starter cable and remove starter motor.

24. ATX only: Remove converter nuts and position mark, made previously, on crankshaft pulley as close to 6 o'clock position (BDC) as possible with converter stud visible.

NOTE: The flywheel timing marker must be in a 6 o'clock (BDC) position for proper engine removal and installation.

25. Remove engine insulator nuts.

26. Disconnect exhaust pipe from manifold.

27. Disconnect canister bracket from engine.

28. Disconnect halfshaft bracket from engine.

29. Remove lower engine-to-transaxle attaching bolts.

30. Disconnect lower radiator hose at tube.

31. Lower hoist and vehicle.

32. Position floor jack under transaxle.

33. Disconnect power steering lines at pump.

34. Install Engine Lifting Eyes D81L-6001-D and Engine Support Tool D87L-6000-A or an equivalent.

35. Attach lifting equipment to support engine and remove upper engine-to-transaxle attaching bolts.

36. Remove engine from vehicle.

37. Mount on stand and remove lifting equipment.

Installation

1. Install Engine Lifting Eyes D81L-6001-D and Engine Support Tool D87L-6000-A or equivalent, and attaching lifting equipment.

NOTE: The flywheel timing marker must be in a 6 o'clock (BDC) position for proper engine removal and installation (ATX only).

2. Remove engine from stand and position in vehicle.

3. Remove lifting equipment and lifting eyes.

4. Install upper engine-to-transaxle bolts, Tighten to specification. Use floor jack under transaxle to aid alignment.

5. Connect power steering lines to pump.

6. Raise vehicle.

7. Connect lower radiator hose to tube.

8. Install lower engine-to-transaxle attaching bolts. Tighten to specification.

9. Connect halfshaft bracket to engine.
10. Connect canister bracket to engine.
11. Connect exhaust pipe to manifold.
12. Install engine insulator nuts. Tighten to specification.
13. ATX only: Position mark on crankshaft pulley as close to 6 o'clock position (BDC) as possible, and install converter nuts. Tighten to specification.
14. Position starter motor and install attaching bolts. Tighten to specification.
15. Connect starter cable.
16. Install oil filter. Check to ensure oil drain plug is installed.
17. Lower vehicle.
18. Install air cleaner-to-canister hose.
19. Install water pump pulley.
20. Install drive belt.
21. MTX only: Install engine damper brace.
22. Connect pressure and suction lines to air conditioning compressor, if so equipped.
23. Connect accelerator cable and throttle valve control cable at throttle body.
24. Connect ground wire at engine.
25. Connect heater hoses at throttle body, 26. Connect fuel lines at throttle body.

27. Connect crankcase ventilation hose at valve cover and intake manifold.
28. Connect engine control sensor wiring assembly and vacuum lines.
29. Connect upper radiator hose at engine.
30. Install air cleaner assembly.
31. Connect battery ground cable.
32. ATX only: Rotate engine until flywheel timing marker is aligned with timing pointer.
33. Install timing window cover at transaxle. 34, Connect electrical connector at inertia switch.
35. Fill cooling system.
36. Fill with proper motor oil to required level.
37. Install hood.
38. Charge air conditioning system, if so equipped.
39. Check all fluid levels (power steering, ATX, MTX).
40. Start vehicle, Check for leaks.


SERVICE PROCEDURES

Engine In Vehicle
NOTE: These Removal and Installation procedures can be performed with the engine in vehicle.


1986-89
21-10-5 Engine, 2.5L 21-10-5

SERVICE PROCEDURES (Continued)

Engine Oil Change (With Filter)

1. Apply parking brake and block wheels. Bring engine to normal operating temperature, and turn off.

2. Remove oil drain plug and inspect gasket. Replace gasket if damaged. Install oil drain plug, and tighten to specification.

3. Remove oil filter and discard. Clean gasket sealing surface at cylinder block or adapter. Coat gasket on filter with a light film of oil Screw filter onto adapter or cylinder block until gasket contacts sealing surface. Then advance it an additional one half turn.

4. Remove oil filler cap, and fill crankcase with specified amount, type and grade of oil.

Install oil filler cap. Start engine and inspect for leaks. Correct as required.


Oil Pump

Removal

1. Remove oil pan as outlined.

2. Remove oil pump attaching bolts and remove oil pump and intermediate driveshaft.

Installation

1. Prime oil pump by filling inlet port with engine oil. Rotate pump shaft until oil flows from outlet port.

2. If screen and cover assembly has been removed, replace gasket. Clean screen and install screen and cover assembly. Tighten two attaching bolts and one nut to specification.

3. Position intermediate driveshaft into distributor socket.

4. Insert intermediate driveshaft into oil pump. Install pump and shaft as an assembly.

CAUTION: Do not attempt to force pump into position if it will not seat. The shaft hex may be misaligned with distributor shaft. To align, remove oil pump and rotate intermediate driveshaft into a new position.

5. Tighten two attaching bolts to specification.

6. Install oil pan and all related parts. Refer to Oil Pan Installation.

7. Fill crankcase to proper level with recommended engine oil. Start engine and check for oil pressure.

Operate engine at fast idle and check for oil leaks.




Oil Pan

Removal
1. Disconnect battery ground cable.

2. Raise vehicle.

3. Drain crankcase.

4. Drain coolant by removing lower radiator hose.

5. Remove roll restrictor (MTX only).

6. Disconnect starter cable.

7. Remove starter.

8. Disconnect exhaust pipe from oil pan.

9. Remove engine coolant tube located at lower radiator hose, at water pump and at tabs on oil pan. Position air conditioner line off to side. Remove oil pan.

Installation

1. Clean both mating surfaces of oil pan and cylinder block with Dupont Freon TF or equivalent.

2. Remove and clean oil pump pickup tube and screen assembly. After cleaning, install tube and screen assembly.
1986-89
21-10-5A Engine, 2.5L 21-10-5A

SERVICE PROCEDURES (Continued)
Oil Pan Installation (Continued)
NOTE: ALWAYS USE RTV ANY TIME SERVICE TO THE OIL PAN IS REQUIRED. DO NOT INSTALL A NEW MOLDED RUBBER OIL PAN GASKET. USE RTV SEALER E8AZ-19562-A (5 FL. OZ).
3. Apply RTV E8AZ-19562-A Sealer or equivalent in the oil pan groove. Completely fill the oil pan groove with sealer. Sealer bead should be 5 mm (.200 inch) wide and 2.0-3.8 mm (.080-.150 inch) high (above the oil pan surface) in all areas except the half-rounds. The half rounds should have a 5 mm (.200 inch) wide and 3.8- 5.1 mm (.150-.200 inch) high (above the oil pan surface) bead.
Caution: Use adequate ventilation when applying sealer.
NOTE: Applying RTV in excess of the specified amount will not improve the sealing of the oil pan, and could cause the oil pickup screen to become plugged with RTV.
4. Immediately (within 5 minutes) install oil pan against cylinder block to prevent RTV from skinning over.
NOTE: RTV needs to cure completely before coming in contact with any engine oil, about one (1) hour cure time at (65-75~ F) ambient temperature.
5. Install two oil pan-to-transaxle bolts. Tighten to 40-50 N-m (30-39 ft.lbs.) to align oil pan with transaxle. Loosen bolts one-half turn.
6. Tighten all oil pan flange bolts to 8-12 N-m (6-9 ft.lbs.).
7. Tighten two oil pan-to-transaxle bolts to 40-54 N-m (30-39 ft.lbs.).
8. Install exhaust pipe bracket to oil pan.
9. Install engine coolant tube and air conditioning line.
10. Install starter and cable.
11. Install roll restrictor (MTX only).
12. Lower vehicle.
13. Install engine oil and coolant.
14. Connect battery ground cable.
15. Start engine and check for leaks.