Engine: Service and Repair

When performing engine removal and installation procedures, check and record the distance between the crankshaft pulley and the frame rail, and the distance between the transmission and frame rail. Models with manual transaxle, check distance at transaxle case. Models with automatic transaxle, check distance at the oil pump housing. This check should be done before the engine is removed and after the engine is installed. If necessary, loosen the motor mount-to-engine bolts to shift the engine to obtain proper engine/transaxle to frame rail clearances. Proper clearances are necessary to ensure half-shaft alignment. Crankshaft pulley-to-frame rail clearance should be .62 inch plus or minus .15 inch. Transaxle to frame rail clearance should be .98 inch plus or minus .19 inch.
1. Mark position of hood hinges, then remove hood.
2. Disconnect battery ground cable, then remove air cleaner, intake duct and heat tube.
3. Remove alternator air intake tube, then drain engine coolant.
4. Remove secondary coil wire, then the alternator drive belt.
5. Remove alternator mount bolts, then position alternator aside.
6. Disconnect thermactor air supply hose at pump, then remove pump.
7. On models with automatic transaxle, disconnect cooler lines at radiator.
8. On all models, disconnect the engine coolant hoses at radiator, then the heater hoses at engine block.
9. Disconnect electric cooling fan, then remove fan and shroud as an assembly.
10. On models with automatic transaxle, remove transaxle coolant line routing clip at radiator.
11. On all models, remove radiator.
12. Disconnect heater at metal tube, then the necessary engine electrical connectors.
13. Disconnect vacuum hoses, then the fuel pump supply and return lines.
14. On models with power assist brakes, disconnect brake booster vacuum hose at engine.
15. On models with automatic transaxle, disconnect kickdown rod at carburetor.
16. On all models, disconnect vacuum hose at thermactor valve.
17. Disconnect accelerator cable at carburetor, then remove cable routing bracket attaching screws.
18. Disconnect vapor hose at carbon canister, then raise and support vehicle.
19. Remove clamp from heater supply and return tubes, then disconnect starter battery cable.
20. Remove knee brace from front of starter motor, then pull starter from vehicle.
21. Disconnect exhaust pipe, then remove support bracket.
22. Remove converter cover on automatic transaxle models or inspection cover on manual transaxle models, then the crankshaft pulley.
23. On models with automatic transaxle, remove torque converter to flywheel attaching bolts, then the converter housing lower attaching bolts.
24. On models with manual transaxle, remove timing belt cover lower attaching bolts, then the flywheel attaching bolts.
25. On all models, loosen coolant bypass hose clamp, then disconnect hose from intake manifold.
26. Remove battery ground cable to engine block attaching bolt, then the No. 3A casting bracket to engine bracket attaching nut and bolt, Fig. 1.
27. Lower vehicle, then attach suitable lifting brackets to engine, then attach lifting device to engine brackets.
28. Remove No. 3A casting to insulator retaining nut, then the casting.
29. On models with manual transaxle, remove remaining timing belt cover attaching bolts, then the cover.
30. On all models, remove insulator attaching bracket from engine, then support transaxle with a suitable jack.
31. Remove upper attaching bolts from converter housing on models with automatic transaxle or flywheel housing on models with manual transaxle.
32. On all models, remove engine from vehicle.
33. Reverse procedure to install.