Engine: Service and Repair

Fig. 1 Engine Replacement:

1. Disconnect battery ground cable.
2. Mark hood hinge location, then remove hood from vehicle. Ensure ground strap near right hand hood hinge is disconnected before removing hood.
3. Drain cooling system, crankcase and transaxle.
4. Remove battery and battery tray, Fig. 1.
5. Remove air cleaner and oil dipstick.
6. Remove engine cooling fan and shroud.
7. Disconnect accelerator cable and speed control cable, if equipped.
8. Disconnect speedometer cable from transaxle.
9. Relieve fuel system pressure by starting engine and disconnecting vane air flow meter. After engine has stalled, place ignition switch in the Off position.
10. Disconnect and cap fuel hoses as necessary permit engine removal.
11. Disconnect radiator and heater hoses.
12. On models with automatic transaxle, loosen transaxle oil cooler line clamps, then disconnect oil cooler lines at transaxle.
13. On all models, disconnect power brake unit vacuum hose.
14. Disconnect evaporative emission control canister hoses.
15. Disconnect engine wiring harness connectors and engine ground strap.
16. Disconnect exhaust pipe from exhaust manifold.
17. Remove A/C compressor and power steering pump and position aside with hoses attached, if equipped.
18. Separate halfshafts from transaxle as follows:
a. Raise and support front of vehicle, then remove necessary underbody covers.
b. Remove stabilizer bar to control arm attaching bolts, nuts, bushings and washers.
c. Remove wheel and tire assemblies.
d. Remove lower ball joint clamp bolt, then separate lower ball joint from steering knuckle.
e. On models with manual transaxle, pull outward on steering knuckle and brake assembly to separate halfshaft from transaxle. If halfshaft is difficult to remove, insert a suitable pry bar between halfshaft and transaxle case. Lightly tap end of pry bar until halfshaft loosens from differential side gear. Suspend halfshaft from chassis using a piece of wire.
f. On models with automatic transaxle, position a suitable pry bar between transaxle case and halfshaft. Light tap end of pry bar until halfshaft loosens from differential side gear. Carefully pull halfshaft out of transaxle and suspend from chassis using a piece wire.
g. On all models, when reinstalling halfshafts, a replacement circlip must be installed.
19. On models equipped with manual transaxle, disconnect clutch cable.
20. On all models, disconnect shift control cable or rod.
21. Remove engine splash shield and inner fender panel.
22. Remove engine mounting attaching bolts, then remove engine and transmission from vehicle as an assembly.
23. Separate engine from transmission.
24. Reverse procedure to install. When installing halfshafts, do not move joints to angles greater than 20 degrees, as damage to seals and boots may result. The halfshaft is properly seated when the shaft circlip snaps into the differential side gear groove.