Engine: Service and Repair

The engine and transaxle must be removed as an assembly.
1. Scribe reference marks between hood and hood hinges, then remove hood.
2. On models equipped with fuel injection, relieve fuel pressure as follows:
a. With engine running, disconnect fuel pump connector.
b. Allow engine to deplete fuel supply, then turn ignition Off. Failure to relieve fuel system pressure prior to disconnecting fuel system components may cause fire or personal injury.
3. On all models, disconnect battery cables, then remove battery and battery tray.
4. Remove air cleaner and engine undercover, if equipped.
5. Drain cooling system into suitable container.
6. On models with automatic transaxle, disconnect transaxle cooling hoses from transaxle.
7. On all models, disconnect heater and the upper and lower radiator hoses from engine, then disconnect cooling fan motor and remove radiator.
8. Mark and disconnect necessary vacuum hoses and engine/transaxle wiring that would interfere with engine removal.
9. Disconnect accelerator cable and brake booster vacuum hose.
10. On models with manual transaxle, disconnect control cable or clutch tube.
11. On models with automatic transaxle, disconnect automatic transaxle control cable. Handle control cable very carefully so as not to bend inner cable.
12. On all models, disconnect speedometer cable.
13. On models equipped with power steering, remove power steering pump and hoses as an assembly leaving hoses connected, then use wire to secure pump.
14. On all models, raise and support vehicle.
15. On models equipped with A/C, remove compressor belt, then remove compressor mounting bolts and compressor leaving refrigerant lines connected. Disconnect compressor wiring, then use wire to secure compressor and hose assembly.
16. On models with manual transaxle, remove shift control rod and extension rod from transaxle. Use wire to secure rods out of the way.
17. On all models, disconnect front exhaust pipe from exhaust manifold.
18. Drain engine oil into suitable container. On models with turbocharged engines, remove oil cooler lines from engine.
19. On all models, disconnect stabilizer bar from lower control arm.
20. Loosen, but do not remove ball joint stud attaching nut, then disconnect ball joint from steering knuckle using puller tool No. MB991113 or equivalent.
21. Loosen, but do not remove tie rod end attaching nut, then disconnect tie rod end from steering knuckle using puller tool No. MB991113 or equivalent.
22. Drain transaxle oil.
23. On models equipped with driveshaft center bearing, remove snap ring securing center bearing, then using plastic hammer, lightly tap D.O.J. (double offset joint) outer race to remove driveshaft from transaxle. Remove center bearing.
24. On models not equipped with driveshaft center bearing, insert suitable pry bar between transaxle case and driveshaft, then pry driveshaft from transaxle case. Do not insert pry bar too deep or oil seal will be damaged. Do not pull on drive axle and do not overextend CV joints, as joints will be damaged.
25. On all models, cover transaxle holes to prevent entry of dirt and replace drive axle circlips.
26. Use wire to secure driveshafts out of the way.
27. Attach suitable engine lifting device, then raise lift enough to tension equipment.
28. Remove front roll stopper insulator bolt, then the rear roll stopper insulator bolt.
29. Remove left mount insulator attaching nut. Do not remove bolt.
30. Raise engine/transaxle assembly enough to remove weight from mounts.
31. Remove blind cover from inside right fender shield, then remove transaxle mount bracket bolt.
32. Remove left mount insulator bolt, then while directing transaxle side down, remove engine/transaxle assembly from vehicle.
33. Separate engine from transaxle as follows:
a. Remove starter motor.
b. On models with automatic transaxle, remove bolts securing torque converter to driveplate.
c. On all models, remove engine-to-transaxle attaching bolts, then remove transaxle assembly.
34. Reverse procedure to install, noting the following:
a. Tighten starter motor bolts to specifications.
b. On models with automatic transaxle, tighten driveplate-to-torque converter bolts to specifications.
c. On all models, torque .47 inch (12mm) engine-to-transaxle bolts to 31-40 ft. lbs.
d. Torque .40 inch (10mm) engine-to-transaxle bolts to 22-25 ft. lbs.
e. Torque .31 inch (8mm) engine-to-transaxle bolts to 7-8 ft. lbs.
f. Tighten left engine mount bolts to specifications.
g. Tighten front engine mount bolts to specifications.
h. Tighten transaxle mount bolts to specifications.
i. Tighten tie rod attaching nuts to specifications.
j. Tighten ball joint attaching nuts to specifications.
k. Tighten exhaust pipe-to-manifold nuts to specifications.