Engine: Service and Repair

1. On models with airbag, disarm airbag system as described under MAINTENANCE PROCEDURES/AIRBAG SYSTEM DISARMING.
2. On all models, disconnect battery ground cable, remove coolant bottle cap, then drain coolant.
3. On DOHC models, lift resonator upward to disengage from engine service support bracket.
4. On all models, remove air cleaner assembly.
5. Disconnect the following electrical connectors:
a. Two coolant temperature sensors.
b. Oxygen sensor and clip, at front transaxle mount bracket.
c. Idles air control valve.
d. Two ignition coil connectors.
e. Manifold absolute pressure sensor.
f. EGR solenoid.
g. Brake booster hose at booster or intake manifold.
h. Two grounds located rear of cylinder head at transaxle.
i. Injector connectors.
6. Disconnect transaxle connectors as follows:
a. Three neutral safety/selector switch.
b. Valve body actuator.
c. Turbine speed sensor.
d. Temperature sensor.
e. Back-up light switch.
7. Disconnect accelerator cables.

Fig. 3 Fuel Line Removal:

8. Bleed fuel pressure using tool No. SST 9127E or equivalent into a suitable container, then disconnect fuel lines using tool No. SA9157E or equivalent, Fig. 3. Place a cloth around fitting before disconnecting.
9. Using wire, tie fuel lines to brake master cylinder, to prevent fuel leakage.
10. Disconnect upper radiator hose and de-aeration hose at engine.
11. Disconnect A/C compressor and position aside.
12. Pinch tabs to disconnect and plug cooler lines at transaxle, then wrap transaxle cooler line fittings with a cloth.

Fig. 3 Fuel Line Removal:

13. On models equipped with automatic transaxle, disconnect shifter cable, Fig. 4.
14. On models equipped with manual transaxle, proceed as follows:
a. Remove hydraulic damper to clutch housing stud nuts, then slide damper and bracket from studs.
b. Rotate clutch actuator 1/4 turn counterclockwise while pushing toward housing to disengage connector and remove.
c. Position clutch hydraulic system aside.
15. On all models, secure radiator, condenser and fan module to front crossbar using wire.
16. Raise and support vehicle.
17. Remove front wheel assemblies, then front and side shields from cradle.
18. Remove brake caliper bracket attaching bolts, then position caliper aside.
19. Disconnect lower radiator and heater inlet and return hoses at engine.
20. Disconnect steering shaft and power steering pressure switch electrical connector, if equipped.
21. Remove front exhaust pipe, catalytic converter, then powertrain stiffener bracket. On 1991 models, remove powertrain stiffening bracket bolts and bracket. Do not remove torque restrictor bracket to transaxle.
22. On all models, remove automatic transaxle flywheel cover and torque converter to flexplate attaching bolts.
23. Remove alternator and starter shields.
24. Disconnect the following electrical connectors:
a. Starter feed.
b. Alternator feed.
c. Oil pressure sensor.
d. Knock sensor.
e. Crankshaft position sensor.
f. EVO solenoid, if equipped.
g. Vehicle speed sensor.
h. Canister purge solenoid.
i. PCM/EC and oxygen sensor.
j. ABS wheel sensor ground connectors, if equipped.
25. Unclip brake lines from rear of cradle, then remove electrical harness from engine, then low vehicle, to lay electrical harness on underhood junction block and battery cover.

Fig. 7 Support Between Torque Strut And Cradle:

26. On models with a torque axis mount system, place a one inch by one inch by 2 inch long block of wood between torque strut and cradle, Fig. 7.
27. Position suitable powertrain support dolly and two four inch by four inch by 36 inch wood pieces to support cradle.
28. Remove cradle to body attaching bolts, then lower cradle, ensuring two large rear cradle spacers are attached.
29. Install suitable engine lifting equipment.
30. Remove spark plug wire ends at ignition module.
31. Remove power steering pump with bracket, then using wire, attach in upright position to steering gear or cradle.
32. Remove transaxle housing attaching bolts.
33. Remove front engine mount, then disconnect motion restrictor, if required.
34. Place 1/2 inch by one inch by three inch block of wood below axle shaft.
35. Remove starter bracket.
36. On DOHC models, remove intake manifold bracket.
37. On all models, remove three axle shaft bracket bolts, then allow bracket to rotate rearward. It may be necessary to lift engine slightly to allow clearance between starter bracket and driveshaft bracket.
38. On models with axis mount system, place a four by four by six inch long block of wood under transaxle housing.

Fig. 8 Removing Engine Strut Bracket And Torque Strut:

39. The engine strut bracket and torque strut are removed as an assembly. The engine may have to lifted just enough for the engine strut removal, Fig. 8.
40. On all models, remove four transaxle housing attaching bolts.
41. Carefully lift engine, then install to engine stand.
42. Remove the following:
a. Starter and alternator.
b. Water pump.
c. Oil Pressure sending unit.
d. Knock sensor.
e. Crankshaft position sensor.
f. Clutch assembly (flexplate) and flywheel.
g. Using tool No. SST SA9123 E or equivalent, cut oil pan seal from front cover oil seal rear seal carrier, then remove oil pan and filter.
h. Oil pick up tube.
i. On DOHC models, remove baffle plate.
43. Reverse procedure to install. On models with airbag, rearm airbag system as described under MAINTENANCE PROCEDURES/AIRBAG SYSTEM DISARMING.