Engine Replace

1. Disconnect battery ground cable.
2. Remove hood.
3. Remove oil filler cap and radiator cap.
4. Raise and support vehicle.
5. Remove both front wheels.
6. Drain engine oil and coolant. Drain enough transaxle oil to avoid leakage when driveshafts are removed.
7. Disconnect starter motor wiring.
8. Disconnect wiring from oil pressure switch.
9. Disconnect lower radiator hose.
10. Remove rubber exhaust supports.
11. Remove exhaust pipe with bracket.
12. Disconnect shift linkage and support rod from transaxle.
13. Separate right and left tie rod ends.
14. Remove clinch bolt and nut and pull lower control arm down to disconnect ball joint from steering knuckle. Repeat on opposite side.

Fig. 1 Removing right hand drive shaft:

15. Insert suitable lever between right driveshaft and joint shaft, Fig. 1, and uncouple driveshaft and joint shaft. Pull front hub forward and separate driveshaft from joint shaft.
16. Remove 3 nuts from engine mount.
17. Lower vehicle.
18. Remove air cleaner assembly.

Fig. 2 Removing air cleaner and wiring:

19. Disconnect Q.S.S. relay and glow plug relay from air cleaner bracket and remove bracket, Fig. 2.
20. Disconnect clutch release cylinder.
21. Remove engine harness bracket.
22. Disconnect engine ground strap from transaxle case.
23. Disconnect speedometer cable from transaxle case.
24. Insert suitable lever between driveshaft and transaxle and uncouple driveshaft end. Take care not to damage transaxle oil seal.
25. Install differential side gear holder 49 G030 455, or equivalent, on transaxle case.

Fig. 3 Disconnecting engine wiring:

26. Disconnect electric cooling fan wiring connector, Fig. 3.
27. Disconnect back-up lamps connector.
28. Disconnect 2 fuel hoses from fuel injection pump.
29. Disconnect glow plug wiring connector.
30. Disconnect RPM sensor connector.
31. Disconnect fuel cut valve connector.
32. Disconnect water temperature sensor connector from thermostat body.
33. Disconnect upper radiator hose from thermostat cover.
34. Disconnect coolant level sensor connector, coolant temperature switch coupler and ground wire.
35. Disconnect coolant overflow hose from radiator.
36. Remove radiator and mounting snubbers.
37. Disconnect accelerator cable from fuel injection pump.
38. Disconnect CSD cable from fuel injection pump, Fig. 3.
39. Disconnect alternator harness.
40. Disconnect brake vacuum hose from pipe.
41. Disconnect 2 coolant hoses from oil cooler.
42. Disconnect oil bypass hoses from oil cooler.
43. Disconnect engine ground cable from body.
44. Remove torque limiter.
45. Remove engine and transaxle from vehicle.
46. Reverse procedure to install.