Engine: Service and Repair

The engine and transaxle are removed as an assembly on these vehicles.
1. Disconnect battery ground cable, and if necessary, remove battery.
2. On models equipped with air conditioning, proceed as follows:
a. Remove crankshaft pulley attaching bolts, then disassemble pulley.
b. Remove A/C compressor drive belt.
c. Disconnect electrical connector from compressor.
d. Remove alternator attaching bolts, then alternator.
e. Remove timing belt cover, the pre-heat hose.
f. Remove compressor mounting and support brace bolts, leaving hoses attached, position compressor assembly aside.
3. On models equipped with automatic transaxle, place shift selector in Park position.
4. Open fuel filler cap to relieve tank pressure.
5. Remove air intake pipe between fuel distributor and throttle valve assembly.
6. Remove radiator cap.
7. Remove thermostat housing to engine attaching bolts, open heater control valve and drain cooling system.
8. Remove thermostat housing, then disconnect upper radiator hose.
9. Mark, then disconnect all electrical connectors from engine.
10. Remove radiator side retaining nuts.
11. Remove upper radiator clip, then the radiator upper clamp.
12. Remove radiator assembly with electric cooling fan from vehicle.
13. Remove pre-heater pipe, then disconnect vacuum hoses from distributor and EGR temperature valve.
14. Remove coil wire, then disconnect heater hoses from engine.
15. Disconnect fuel line from cold start valve and warm-up regulator.
16. On automatic transaxle models, disconnect speedometer cable.
17. Disconnect vacuum hoses from brake booster, front and rear vacuum amplifiers and vacuum booster (if equipped).
18. Disconnect PCV hose.
19. On manual transaxle models, disconnect accelerator cable from linkage ball stud and cylinder head cover attaching bracket.
20. Remove fuel injectors, fuel lines and vacuum hoses and position aside.
21. On models with 16 valve engine, remove intake manifold.
22. Disconnect ground cable strap from transaxle.
23. On manual transaxle models, disconnect clutch cable from clutch lever and speedometer cable from transaxle, then remove upper starter bolt.
24. On automatic transaxle models, disconnect selector cable and accelerator pedal cable from transaxle bracket, then disconnect accelerator pedal cable from operating rod.
25. Remove nuts and bolts securing exhaust flex pipe to exhaust manifold.
26. On manual transaxle models, remove relay shaft retaining nut and relay shaft.
27. Disconnect driveshafts from transaxle drive flanges.
28. On manual transaxle models, remove starter.
29. Remove horn assembly and position aside.
30. Remove front mount cup to body attaching bolts, then the front mount and cup.
31. Remove both driveshaft to bearing housing attaching bolts, then the ball joint lock bolts.
32. Separate both ball joints from bearing housings, then remove both drive shafts from vehicle. After removing driveshafts, connect ball joints and lock bolts to enable vehicle to be lowered.
33. Remove rear transaxle mount and right front wheel/tire assembly.
34. Attach engine replacement tool US-1105 or equivalent and lift engine slightly with hoist. Always attach lifting eye tool 055103390A to cylinder head when removing engine to ensure equal weight distribution.
35. On manual transaxle models, disconnect all shift linkages that will interfere with engine/transaxle removal.
36. Remove left and right side engine mount to body attaching bolts, then the mounts.
37. Lower engine/transaxle assembly onto suitable floor dolly, raise vehicle and remove engine/transaxle assembly out from underneath vehicle.
38. On models with 16 valve engine, attach engine sling 2024A or equivalent, and lift engine/transaxle out (upward), rotating engine slightly at the same time.
39. Reverse procedure to install.