Engine: Service and Repair

1. Relieve fuel system pressure as outlined under Technican Safety Information.
2. Disconnect battery cables from battery, then remove battery from vehicle.
3. Drain cooling system.
4. Disconnect radiator hoses from engine, then the radiator cooling fan motor electrical connectors.
5. Remove V-belt cover, then the reservoir tank.
6. Remove radiator retaining brackets. Lift and position radiator slightly to the left.
7. Disconnect automatic transaxle fluid cooler hoses from radiator.
8. Remove radiator from vehicle.
9. On models equipped with A/C, properly discharge A/C system.
10. Disconnect and plug discharge and suction hoses. Ensure care is taken not to loose O-ring in low pressure hose.
11. Remove resonator chamber.
12. Remove air cleaner upper cover and air filter.
13. Remove turbocharger cooling duct, then the air inlet and outlet ducts.
14. Remove emission canister and bracket, then disconnect heater and brakes booster hoses.
15. Disconnect coolant filler tank and pressure control hoses.
16. Remove power steering pump as follows:
a. Loosen alternator adjusting and lock bolts, then remove V-belt.
b. Disconnect right side spark plugs wires.
c. Remove pipe and bracket from intake manifold.
d. Remove power steering pump retaining bolts and position pump aside.
17. Separate center exhaust pipe from turbocharger unit.
18. Raise and support vehicle.
19. Remove turbocharger lower cover.
20. Remove center exhaust pipe from vehicle.
21. Remove clutch damper and bracket.
22. Remove lower starter mounting nut, then the lower transaxle to engine nuts.
23. Remove front cushion rubber to front crossmember mounting nuts, then the starter.
24. Separate clutch release fork from release bearing as follows:
a. Remove clutch operating cylinder from transaxle.
b. Using 10 mm hex wrench, remove plug.
c. Screw 6 mm diameter bolt into release fork shaft, then remove shaft.
d. Raise release fork and unfasten release bearing tabs to free fork.
25. On models equipped with automatic transaxle, separate torque converter from driveplate.
26. Remove pitching stopper, then disconnect fuel hoses.
27. Support engine with suitable lifting device and transaxle with suitable stand.
28. Remove upper side transaxle to engine bolt.
29. Slightly raise engine and transaxle. Move engine horizontally until mainshaft is out of clutch cover.
30. Remove engine from vehicle.
31. Reverse procedure to install noting the following:

Fig. 2 Front Rubber Cushion Installation:

Fig. 3 Engine Mount Clearance:

a. When tightening front rubber cushion mounting bolts ensure they are positioned as shown in Fig. 2. Also, ensure clearance H is .16-.24 inch as shown in Fig. 3.
b. Tighten all bolts and nuts to specifications.
c. Refer to Drive Belt for belt routing and tension data.
d. Refer to Cooling System / Service and Repair for drain and refill procedure.