Acura Coupes and Sedans 1986-1993 Repair Guide

Engine Assembly

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REMOVAL & INSTALLATION



1986-1989 Integra

See Figures 1 and 2

On these vehicles, the engine and transaxle are removed as a unit. The lower ball joints and the inner CV-joints will be separated but not removed.

  1. Disconnect the battery cables from the battery; negative cable first. Remove the battery and the battery tray from the engine compartment, if necessary.
  2.  
  3. Using a scratch awl, scribe a line where the hood brackets meet the inside of the hood; this will help realign the hood during the installation. Disconnect and remove the washer fluid tube(s). Remove the hood-to-hinge bolts and the hood.
  4.  
  5. Raise and safely support the vehicle. Remove the engine and wheel well splash shields.
  6.  
  7. Drain the oil from the engine, the coolant from the radiator and the fluid from the transaxle.
  8.  
  9. Remove the following items:
    1. The engine air intake ducts.
    2.  
    3. The coil wire and spark plug wires.
    4.  
    5. The throttle control cable.
    6.  
    7. The cruise control throttle cable.
    8.  
    9. The clutch cable.
    10.  

  10.  
  11. Relieve the fuel pressure by slowly loosening the service bolt on the top of the fuel filter.
  12.  


CAUTION
The fuel system may be under pressure and fuel will be sprayed. Be sure there is good ventilation and take the appropriate fire safety precautions.

  1. Remove the banjo bolt and disconnect the fuel hose from the filter.
  2.  
  3. Label and disconnect the engine compartment sub-harness wiring connectors.
  4.  
  5. Most of the vacuum hoses lead to an emissions control equipment box or panel on the firewall. Rather than disconnecting the hoses, it may be easier to disconnect the wiring, remove the box or panel and lay it on the engine. All other vacuum hoses can be labeled and disconnected.
  6.  
  7. Loosen the throttle cable locknut and adjusting nut, then, slip the cable end out of the throttle bracket and remove it.
  8.  
  9. Without disconnecting the hydraulic lines, remove the power steering pump and secure it to the body out of the way.
  10.  
  11. If equipped with an automatic transaxle, working inside the vehicle, remove the center console. Move the shift lever to the R position and remove the lock pin to separate the shift cable.
  12.  
  13. If equipped with a manual transaxle, at the firewall, slide the spring pin retainer towards the front of the vehicle. Use an 8mm pin punch to drive the spring pin out to separate the shift rod.
  14.  
  15. Label the heater hoses and disconnect the heater and radiator hoses from the engine.
  16.  
  17. On vehicles equipped with automatic transaxle, disconnect the oil cooler hoses from the Transaxle and allow the fluid to drain from the hoses. Secure the hoses to the body near the radiator.
  18.  
  19. Disconnect the upper and lower radiator hoses and the wiring for the switches and fans. Remove the bolts and remove the radiator and fans as an assembly.
  20.  
  21. Remove the speedometer cable clip and pull the cable from the holder.
  22.  

Do not remove the holder from the transaxle as it may cause the speedometer gear to fall into the transaxle.

  1. If equipped with air conditioning, loosen the drive belt adjusting bolts and remove the belt. Without disconnecting the hoses, remove the compressor and secure it to the body. Remove the lower compressor mounting bracket.
  2.  

Do not loosen or disconnect the air conditioning freon lines. Do not vent freon into the air.

  1. Disconnect the alternator wiring harness connector. Remove the adjusting bolt and the alternator belt. Remove the mount bolt, bracket and the alternator.
  2.  
  3. Disconnect the exhaust pipe from the manifold.
  4.  
  5. Remove the cotter pin and nut from the ball joints. Using a ball joint puller, separate the ball joint from the front hub.
  6.  
  7. Using a small prybar, pry out the inboard CV-joint approximately 1 / 2 in. (13mm) in order to release the spring clip from the groove in the differential. Pull the steering knuckle assembly outward. Pull the halfshaft from the transaxle case. Secure the halfshafts out of the way. Do not let them hang or the outer CV-joint will be damaged.
  8.  
  9. Attach a lifting sling to the engine block and raise the engine slightly to remove the slack from the chain.
  10.  
  11. Remove the rear transaxle mount and the bolts from the front transaxle mount and the engine side mount.
  12.  



Click image to see an enlarged view

Fig. Fig. 1: Engine mount locations-1986-90 Vigor



Click image to see an enlarged view

Fig. Fig. 2: Engine mount torque specifications-1986-90 Integra

  1. Check that the engine and transaxle are free from any hoses or electrical connectors. Slowly raise the engine up and out of the vehicle.
  2.  

To install:
  1. Carefully fit the engine and transmission into the vehicle. Be careful not to damage any hoses or electrical connectors.
  2.  
  3. Loosely install the rear transaxle mount and the bolts for the front transaxle mount and the engine side mount. Tighten the bolts in 2 steps in the sequence shown. This is important to help minimize vibration.
  4.  
  5. Fit the halfshafts into place. Use new spring clips and be sure the CV-joints click into place.
  6.  
  7. Reconnect the ball joints and torque the nut to 33 ft. lbs. (45 Nm). Install a new cotter pin.
  8.  
  9. Connect the exhaust pipe with new self locking nuts and torque to 40 ft. lbs. (55 Nm).
  10.  
  11. Reinstall the alternator and the air conditioning compressor.
  12.  
  13. Install the drive belts and adjust the belt tension.
  14.  
  15. Install the speedometer cable.
  16.  
  17. Install the radiator assembly, coolant hoses, heater hoses and oil cooler lines.
  18.  
  19. Connect the shift linkage and adjust the clutch cable.
  20.  
  21. Install the power steering pump and drive belts. Install the throttle cable bracket and throttle cable.
  22.  
  23. Install the control box or panel to the firewall. Reconnect all disconnected vacuum lines and electrical connectors.
  24.  
  25. Make sure all hoses, wires and control cables are properly connected and adjusted.
  26.  
  27. Install the battery box, battery and battery cables. When installing the hood, be sure to line the hood up with the scribe marks made during the removal procedure.
  28.  
  29. Install the wheel well and engine splash shields.
  30.  
  31. Refill the coolant system, engine oil and transaxle fluid. Start the engine, bleed the cooling system and make all necessary adjustments.
  32.  

1990-93 Integra

See Figures 3, 4 and 5

On these vehicles, the engine and transaxle are removed as a unit. The lower ball joints and the inner CV-joints will be separated but not removed.

  1. Raise and safely support the vehicle. Remove the engine and wheel well splash shields.
  2.  
  3. Disconnect the battery cables from the battery, negative cable first. Remove the battery and the battery tray from the engine compartment.
  4.  
  5. It is not necessary to remove the hood. Raise it to a full vertical position and support it properly.
  6.  
  7. Drain the oil from the engine, the coolant from the radiator and the fluid from the transaxle.
  8.  
  9. Remove the intake air duct and air cleaner assembly.
  10.  
  11. Remove the fuel filler cap and loosen the service bolt on the fuel filter banjo bolt to relieve the fuel pressure. Disconnect the fuel feed hose from the fuel filter and the fuel return hose from the pressure regulator.
  12.  


CAUTION
The fuel system may be under pressure and fuel will be sprayed. Be sure there is good ventilation and take the appropriate fire safety precautions.

  1. Disconnect the charcoal canister hose from the throttle body. Vehicles with automatic transaxle have an emissions control equipment box on the firewall. Rather than disconnecting the vacuum hoses, it may be easier to unplug the connectors, remove the box from the firewall and lay it on the engine.
  2.  
  3. Remove the ground cable from the transaxle. Disconnect the 2 distributor electrical connectors, make an alignment mark on the distributor body and the engine and remove the distributor.
  4.  
  5. Remove the throttle cable by loosening the locknut, then slip the cable end out of the throttle bracket and accelerator linkage. Take care not to bend the cable when removing it. Do not use pliers to remove the cable from the linkage.
  6.  
  7. Remove the mounting bolts and the V-belt for the power steering pump, then without disconnecting the hoses, secure the pump out of the way.
  8.  
  9. Near the brake booster, disconnect the engine wiring harness connectors and remove the wire from the clamp.
  10.  
  11. Remove the brake booster vacuum hose from the intake manifold. Disconnect the upper and lower radiator hoses and heater hoses.
  12.  
  13. Without disconnecting the hydraulic hoses or cable, remove the bolt to remove the speed sensor from the transaxle as an assembly.
  14.  
  15. Disconnect the transaxle cooling hoses, if equipped, and unplug the radiator fan connectors. Remove the radiator and fans as an assembly.
  16.  
  17. If not already removed, remove the driver's side splash shield at the wheel well.
  18.  
  19. If equipped with air conditioning, remove the belt. Remove the compressor with the hoses still attached and secure the compressor to the front beam.
  20.  

Do not loosen or disconnect the air conditioning freon lines. Do not vent freon into the air.

  1. To disconnect the halfshafts, the lower damper fork and ball joint must be disconnected, allowing the steering knuckle to move away from the transaxle.
    1. With the front wheels removed, remove the damper fork nut and pinch bolt. Remove the damper fork from the lower arm.
    2.  
    3. Remove the lower ball joint castle nut press the ball joint out of the lower arm using a suitable puller, with the puller jaws grasping the lower arm.
    4.  
    5. Carefully pry the inner CV-joint away from the Transaxle to force the set ring at the inner end past the groove.
    6.  
    7. Pull the inboard CV-joint, not the halfshaft, and remove the CV-joint out of the intermediate shaft.
    8.  

  2.  

Do not pull on the halfshaft, as the CV-joint may come apart. Use care when prying out the assembly and pull it straight to avoid damaging the intermediate shaft seals.

    1. Support the halfshafts or hang them from the body with wire. Do not let them hang from the outer CV-joint or it will be damaged.
    2.  


  1. Disconnect the alternator wiring harness connector. Remove the alternator belt, the mount bolts, the alternator and the mounting bracket.
  2.  
  3. Remove the front exhaust pipe.
  4.  
  5. If equipped with a manual transaxle, perform the following procedures:
    1. Disconnect the clutch cable. Avoid using pliers to remove the cable from the linkage.
    2.  
    3. To disconnect the shift linkage rod, push back the boot and drive out the pin securing the shift rod universal joint to the transaxle. Use a new pin when reassembling.
    4.  
    5. Remove the shift lever torque rod.
    6.  

  6.  
  7. If equipped with an automatic transaxle, remove the torque converter cover. Remove the cable holder, cotter pin and control pin, then remove the shift control cable. Take care not to bend the cable when removing it. Avoid using pliers to remove the cable from the linkage.
  8.  
  9. Attach a suitable lifting device to the engine. Raise the engine slightly to remove all the slack from the lifting device.
  10.  
  11. Remove the rear transaxle mount and rear transaxle mounting bracket.
  12.  



Click image to see an enlarged view

Fig. Fig. 3: Engine mount locations-1991-93 Integra



Click image to see an enlarged view

Fig. Fig. 4: Engine mount torque sequence and specifications-1991-93 Integra



Click image to see an enlarged view

Fig. Fig. 5: Additional engine torque specifications-1991-93 Integra

  1. Remove the front transaxle mount. Remove the side transaxle mounting bracket. Remove the side engine mount.
  2.  
  3. Check that the engine/transaxle assembly is completely free of all vacuum hoses and electrical wires.
  4.  
  5. Slowly raise the engine approximately 6 inches and check again.
  6.  
  7. Raise the engine/transaxle assembly all the way and remove it from the vehicle. Place the engine on a suitable engine stand assembly.
  8.  

To install:
  1. Slowly lower the engine and transaxle assembly into the vehicle.
  2.  
  3. Check that the engine and transaxle are free from any hoses or electrical connectors.
  4.  
  5. Install the mounts and bolts. Some of the transaxle mount bolts are designed to be torqued only one time and must be replaced whenever the engine is removed. Be sure to torque all bolts in 2 steps in the sequence shown. This is important to help minimize engine vibrations.
  6.  
  7. If equipped with an automatic transaxle, reinstall the control pin, cotter pin, cable holder and cable. Install the torque converter cover.
  8.  
  9. If equipped with a manual transaxle, install the shift rod and the shift torque rod. Connect the clutch cable and check the clutch adjustment.
  10.  
  11. Install the front exhaust pipe with new self locking nuts and torque to 40 ft. lbs. (55 Nm).
  12.  
  13. Reinstall the alternator assembly.
  14.  
  15. Install the halfshaft assemblies. Be sure to use new set rings.
  16.  
  17. Reinstall the air conditioning compressor and drive belts.
  18.  
  19. Install the speedometer drive.
  20.  
  21. Reinstall the radiator assembly, coolant hoses, heater hoses and oil cooler lines.
  22.  
  23. Reinstall the power steering pump and drive belts. Install the throttle cable bracket and throttle cable.
  24.  
  25. Reinstall the distributor assembly and ground cable to the transaxle.
  26.  
  27. Reinstall the control box brackets and control box connectors. Reconnect all disconnected vacuum lines and electrical connectors.
  28.  
  29. Reinstall the battery box, battery and battery cables.
  30.  
  31. Reinstall the wheel well and engine splash shields.
  32.  
  33. Carefully check to make sure all wires, hoses, belts and control cables are connected and properly adjusted.
  34.  
  35. Refill the coolant system, engine oil and transaxle fluid. Start the engine, bleed the cooling system and make all necessary adjustments.
  36.  

1986-90 Legend

See Figures 6, 7, and 8

On these vehicles, the engine and transaxle are removed as a unit. The lower ball joints and the inner CV-joints will be separated but not removed.

  1. Raise and safely support the vehicle.
  2.  
  3. Disconnect both battery cables from the battery. Remove the battery and the battery tray from the engine compartment.
  4.  
  5. Position the hood in the vertical position by removing the prop mounting bolt on the hood side and fitting it to the mounting hole near the hinge.
  6.  
  7. Remove the air intake tube, air cleaner and resonator tube as an assembly.
  8.  
  9. Remove the splash guard from under the engine.
  10.  
  11. Remove the oil filler cap and drain plug to drain the engine oil.
  12.  
  13. Remove the radiator cap, then open the radiator drain petcock and drain the coolant from the radiator. There are also block drain bolts on each side of the engine.
  14.  
  15. Remove the transaxle filler plug, then remove the drain plug and drain the transaxle.
  16.  
  17. Disconnect the pressure switch wire from the oil filter base.
  18.  
  19. Disconnect both water hoses from the engine oil cooler.
  20.  
  21. Remove the drain bolt from the oil filter base to drain the oil. Remove the oil filter base from the engine block.
  22.  
  23. Disconnect the upper and lower radiator hoses from the radiator.
  24.  
  25. If equipped with an automatic transaxle, disconnect cooler hose from the bottom of the radiator.
  26.  
  27. Disconnect the following engine sub-harness connectors from the body side:
    1. Four right side connectors and clamp
    2.  
    3. Both left side main fuse connectors
    4.  
    5. Coil wire, primary lead connectors and the condenser connector.
    6.  
    7. Both ground cables from the cylinder head and the transaxle.
    8.  

  28.  
  29. Disconnect the connector from the power steering pump and both hoses. Disconnect the hose from the cruise control actuator and the hose from the power brake booster.
  30.  
  31. To relieve the fuel system pressure, place a shop rag over the fuel filter to absorb any gasoline which may be sprayed on the engine while relieving the pressure. Slowly loosen the service bolt approximately one full turn. This will relieve any pressure in the system. Using a new sealing washer, tighten the service bolt.
  32.  


CAUTION
The fuel system may be under pressure and fuel will be sprayed. Be sure there is good ventilation and take the appropriate fire safety precautions.

  1. Disconnect the fuel return hose from the pressure regulator. Remove the banjo bolt and the fuel hose.
  2.  
  3. Disconnect the throttle cable from the throttle body. Label and disconnect the vacuum hoses coming from the emission control equipment box.
  4.  
  5. Remove the speed sensor as an assembly from the transaxle.
  6.  
  7. The air conditioning compressor can be moved without discharging the air conditioning system. Remove the air conditioning compressor as follows:
    1. Remove the compressor clutch lead wire.
    2.  
    3. Loosen the belt adjusting bolt.
    4.  
    5. Remove the compressor mounting bolts, then lift the compressor out of the bracket with the hoses attached and hang it to the front bulkhead with a piece of wire.
    6.  

  8.  

Do not loosen or disconnect the air conditioning freon lines. Do not vent freon into the air.

  1. If equipped with an automatic transaxle, remove the center console. Place the shift lever in R , then remove the lock pin to separate the shift cable.
  2.  
  3. If equipped with a manual transaxle, at the shift rod universal joint, slide the pin retainer forward and drive out the spring pin. Separate the shift rod universal joint from the transaxle. Remove the banjo bolt to disconnect the clutch hydraulic hose from the clutch damper on the transmission. Catch and discard the hydraulic fluid that leaks out.
  4.  
  5. Remove the exhaust pipe from the front and rear manifolds.
  6.  
  7. Remove the halfshaft as follows:
    1. Raise and safely support the vehicle and remove the front wheels.
    2.  
    3. Remove the ball joint bolt and separate the ball joint from lower control arm.
    4.  
    5. Using a small prybar, pry out the inboard CV-joint approximately 13mm in order to release the spring clip from the differential, then pull the halfshaft from the transaxle case.
    6.  
    7. Cover the inner CV-joints with a plastic bag and hang the halfshaft from the body with wire. Do not let the halfshafts hang by the outer CV-joint or it will be damaged.
    8.  

  8.  
  9. Attach a suitable lifting chain to the engine and raise it enough to remove the slack.
  10.  



Click image to see an enlarged view

Fig. Fig. 6: Engine mount locations-1986-90 Legend



Click image to see an enlarged view

Fig. Fig. 7: Engine mount torque sequence and specifications-1986-90 Legend



Click image to see an enlarged view

Fig. Fig. 8: Additional engine mount torque specifications-1986-90 Legend

  1. Remove the engine side mount bracket bolts.
  2.  
  3. Remove the front engine mount nut, then remove the rear engine mount nut.
  4.  
  5. Loosen and remove the alternator belt. Disconnect the alternator wire harness and remove the alternator.
  6.  
  7. Remove the bolt from the rear torque rod at the engine, then loosen the bolt in the frame mount and swing the rod up and out of the way.
  8.  
  9. Tilt the engine about 30 degrees and raise the engine carefully from the vehicle checking that all wires and hoses have been removed from the engine/transaxle. Raise the engine all the way up and remove it from the vehicle.
  10.  

To install:
  1. Carefully fit the engine and transaxle into the vehicle.
  2.  
  3. Check that the engine and transaxle are free from any hoses or electrical connectors.
  4.  
  5. Install the transaxle and engine mounts and bolts. Some of the bolts in upper rear mount are designed to be torqued only one time and must be replaced whenever they are removed. Be sure to torque all bolts in 2 steps in the sequence shown in the illustration. This is important to help minimize engine vibrations.
  6.  
  7. If equipped with automatic transaxle, reinstall the control pin, cotter pin, cable holder and cable. Install the torque converter cover.
  8.  
  9. Reconnect the shift cable and reinstall the center console assembly.
  10.  
  11. If equipped with manual transaxle, connect the clutch hydraulic line, gear shift linkage and torque rod.
  12.  
  13. Install the front and rear exhaust pipes.
  14.  
  15. Reinstall the alternator assembly.
  16.  
  17. Install the halfshaft assemblies. Use new clips on the CV-joints and make sure they click firmly into place. Torque the lower ball joint nut to 72 ft. lbs. (100 Nm) and install a new cotter pin.
  18.  
  19. Reinstall the air conditioning compressor and drive belts.
  20.  
  21. Install the speedometer drive assembly.
  22.  
  23. Reinstall the radiator assembly, coolant hoses, heater hoses and oil cooler lines.
  24.  
  25. Reconnect the power steering hoses and refill the reservoir to the upper mark. Install the throttle cable bracket and throttle cable.
  26.  
  27. Install the distributor assembly and ground cable to the transaxle.
  28.  
  29. Install the control box brackets and control box connectors. Reconnect all disconnected vacuum lines and electrical connectors.
  30.  
  31. Reinstall the battery box, battery and battery cables. Install the hood back to its proper position.
  32.  
  33. Install the wheel well and engine splash shields.
  34.  
  35. Refill the coolant system, engine oil and transaxle fluid. Start the engine and bleed the steering system by turning the steering wheel lock-to-lock several times. Bleed the cooling system by opening the bleeder screw near the thermostat housing. Make all other necessary adjustments.
  36.  

1991-93 Legend

See Figures 9, 10 and 11

Portions of the front sub-frame are made of aluminum alloy. Using normal steel bolts on aluminum will cause an electrolytic reaction: the aluminum around the fastener will corrode and the bolt will loosen. When replacing fasteners, be sure to use bolts that have a Dacro® coating specifically designed for such applications. Dacro® bolts can be identified by a dull grey finish, sometimes with a dull green finish on the threads for more accurate torque wrench readings. These parts should be available at the dealer.

On this vehicle, the engine and transaxle are lifted out as a unit. The battery will also be removed. Since the vehicle is equipped with a theft protected radio, it is important to have the security code before disconnecting the battery. After reconnecting power to the radio, the 5 digit code must be entered to restore operation.

  1. Do not remove the hood. Disconnect the hood stay strut and reconnect it to hold the hood in a vertical position. Remove the battery and the battery box.
  2.  
  3. Remove the strut bar that runs across the engine compartment and the bracket. Working underneath the vehicle, remove the splash shield and drain the engine coolant and oil and the transaxle fluid.
  4.  
  5. Label and disconnect the starter and battery wiring from the main fuse/relay box. Remove the ground cable from the engine block and label and disconnect the main engine wiring harness.
  6.  
  7. Remove the throttle cable cover. Without turning the adjusting nut, loosen the locknut, which is closer to the throttle, and disconnect the throttle cable from the throttle and bracket.
  8.  
  9. Remove the air cleaner assembly and ducting.
  10.  
  11. On the right shock tower, disconnect the igniter unit and remove the wiring harness clamp. Disconnect the engine ground cable.
  12.  
  13. On the firewall behind the right cylinder head is a control box containing emission control equipment. Without disconnecting any vacuum hoses, unplug the electrical connectors and remove the control box from the firewall. Lay the box on top of the engine.
  14.  
  15. Label and disconnect the main engine wiring harness connectors and remove the bracket.
  16.  
  17. On top of the fuel filter, relieve the fuel system pressure by slowly loosening the service bolt 1 turn.
  18.  


CAUTION
The fuel system may be under pressure and fuel will be sprayed. Be sure there is good ventilation and take the appropriate fire safety precautions.

  1. Remove the fuel supply hose and disconnect the return hose from the pressure regulator.
  2.  
  3. Disconnect the vacuum hose to the brake booster at the check valve.
  4.  
  5. At the left rear of the engine compartment, disconnect the transaxle wiring harness and remove the clamp.
  6.  
  7. Disconnect and plug the transaxle cooling hoses at the radiator. Disconnect the upper and lower hoses and the fan and sensor wiring. Remove the radiator and fans as an assembly.
  8.  
  9. Near the power steering fluid reservoir, remove the solenoid valve assembly, vacuum pipes and air tank.
  10.  
  11. Without disconnecting any hoses, remove the power steering pump and secure it out of the way.
  12.  
  13. Raise and safely support the vehicle and remove the front wheels.
  14.  
  15. Remove the lower damper forks and remove the nut from the lower ball joint. Use a suitable ball joint removal tool to disconnect the ball joint from the lower control arm.
  16.  
  17. Carefully pry the inner CV-joints from the transaxle and hang the halfshafts from the suspension. Do not let the halfshaft hang by the outer CV-joint or the joint will be damaged. Cover the inner joints with plastic bags.
  18.  
  19. Remove the lower plate from the rear beam.
  20.  
  21. Without disconnecting any hoses, remove the power steering speed sensor from the differential housing.
  22.  
  23. Disconnect the exhaust pipe from the catalyst and remove it from the manifolds.
  24.  
  25. Without disconnecting any hoses, remove the air conditioner compressor and hang it from the body with wire.
  26.  

Do not loosen or disconnect the air conditioning freon lines. Do not vent freon into the air.

  1. On vehicles with a manual transaxle, remove the clutch slave cylinder without disconnecting the hydraulic line. Disconnect the shift lever torque rod and disconnect the shift linkage by driving out the 8mm roll pin.
  2.  



Click image to see an enlarged view

Fig. Fig. 9: Engine mount torque sequence-1991-93 Legend



Click image to see an enlarged view

Fig. Fig. 10: Engine mount torque specifications-1991-93 Legend



Click image to see an enlarged view

Fig. Fig. 11: Front and rear sub-frame mounting-1991-93 Legend

  1. Remove the engine mid-mount nuts and bolts and the transaxle rear mount.
  2.  
  3. Working from above, remove one of the EGR valve passage bolts and install a lifting hook. Attach a chain hoist and take up the slack.
  4.  
  5. Remove all engine and transaxle mounting nuts and bolts. Raise the engine/transaxle slightly and check to make sure all hoses and wires have been disconnected. As the unit is raised, allow it to tilt up in front to provide proper clearance past the rear beam.
  6.  

To install:
  1. When installing the engine/transaxle, rotate the unit up in front to avoid hitting the rear beam with the transaxle. Check carefully to make sure the rubber mounts are not twisted or offset. Start all the nuts and bolts and then torque them in the order shown in the illustration. This is important to help minimize engine vibrations.
  2.  
  3. After the mounts have been properly torqued, install the mounting bolts on the rear transaxle mount and torque to 28 ft. lbs. (39 Nm). Install the engine mid-mounts and torque the nuts and bolts to 28 ft. lbs. (39 Nm). Remove the lifting hook and install the EGR valve passage bolt.
  4.  
  5. Reconnect the shift linkage. On vehicles with a manual transaxle, install the clutch slave cylinder.
  6.  
  7. Install the air conditioner compressor and torque the mounting bolt to 16 ft. lbs. (22 Nm). Adjust the belt tension for about 1 / 4 in. of deflection with 22 lbs. (10 kg) force and torque the idler pulley nut to 33 ft. lbs. 45 Nm).
  8.  
  9. When installing the exhaust pipe, use new gaskets and self locking nuts. Torque the manifold nuts to 40 ft. lbs. (55 Nm) and the catalyst flange nuts to 16 ft. lbs. (22 Nm).
  10.  
  11. Install the power steering speed sensor and connect the wiring. Torque the bolts to 9 ft. lbs. (12 Nm).
  12.  
  13. Install the lower plate using the special corrosion resistant bolts. Torque to 29 ft. lbs. (39 Nm).
  14.  
  15. Install new clips to the end of the inner CV-joints and press the joints into the transaxle. Make sure joint clicks solidly into place. When assembling the suspension, torque the lower ball joint nut to 51-58 ft. lbs. (70-80 Nm). Torque the lower damper bolt to 51 ft. lbs. (70 Nm) and the upper damper pinch bolt to 37 ft. lbs. (51 Nm).
  16.  
  17. Install the power steering pump and adjust the belt tension for about 1 / 2 inch deflection with 22 lbs. (10 kg) force. Torque the mounting bolt to 33 ft. lbs. (45 Nm) and the nut to 16 ft. lbs. (22 Nm).
  18.  
  19. Install the radiator and connect the cooling hoses. When filling the system, open the bleeder where the upper hose connects to the engine.
  20.  
  21. Install the emission control equipment bracket and connect wiring and vacuum hoses.
  22.  
  23. Install the fuel supply pipe, using new gaskets. Connect the return hose and the brake booster vacuum hose. Finish connecting all the remaining wiring and vacuum hoses, except for the battery.
  24.  
  25. Install the throttle cable. If the adjuster nut (farther from the boot) has been moved, temporarily tighten the lock nut. The engine must be fully warmed up to adjust the cable.
  26.  
  27. Install the air cleaner and ducting, strut bar and splash shield.
  28.  
  29. Refill the engine oil and transaxle fluid and install the battery. When the battery is connected, turn the ignition switch ON and OFF a number of times to pressurize the fuel system and check for leaks.
  30.  
  31. After checking carefully and making sure everything is properly connected, start the engine and bleed the cooling system. When the engine is at operating temperature, stop the engine and adjust the throttle cable.
  32.  
  33. To adjust the throttle cable, loosen both nuts and take up the slack in the cable. Back the adjusting nut away from the bracket so there is 0.120 in. (3.0mm) gap between the nut and bracket. Make sure the throttle opens and closes fully with pedal movement.
  34.  

Vigor

See Figures 12 and 13

On these vehicles, the engine and differential are removed as a unit but the transmission remains in the vehicle. The lower ball joints and the inner CV-joints will be separated but not removed. The radio is equipped with a theft protection program. Be sure the 5 digit security code is available before disconnecting the battery.

  1. Disconnect the negative battery cable. Raise and safely support the vehicle and remove the engine splash shield.
  2.  
  3. Drain the engine oil and coolant and the fluid from the transmission and differential.
  4.  
  5. It is not necessary to remove the hood. Raise it to a full vertical position and support it properly.
  6.  
  7. Label and disconnect the wiring from the ignition coil and from the ABS relay box.
  8.  
  9. Remove the ABS relay box and heat shield and remove the battery.
  10.  
  11. Remove the intake air duct and air cleaner assembly.
  12.  
  13. Remove the fuel filler cap and loosen the service bolt on the fuel filter banjo bolt to relieve the fuel system pressure. Remove the banjo bolt to remove the fuel feed hose from the fuel filter. Remove the fuel return hose from the pressure regulator.
  14.  


CAUTION
The fuel system may be under pressure and fuel will be sprayed. Be sure there is good ventilation and take the appropriate fire safety precautions.

  1. Remove the throttle cable by loosening the locknut, then slip the cable end out of the throttle bracket and accelerator linkage. Take care not to bend the cable when removing it. Unbolt the throttle cable clamp and move the cable aside.
  2.  
  3. Label and disconnect all the engine wiring harnesses.
  4.  
  5. Disconnect the charcoal canister hoses, fuel return hose, brake booster hose and the emission control vacuum hose.
  6.  
  7. Disconnect the heater hoses and the transmission wiring connector that is near the heater hoses.
  8.  
  9. Disconnect the wiring and remove the 2 bolts to remove the distributor. Be careful not to lose the collar that is behind the distributor.
  10.  
  11. Label and disconnect the wiring as required from the relay box under the hood. Disconnect the ground cables in the same area.
  12.  
  13. Without disconnecting the hoses, remove the power steering pump and the air conditioner compressor and secure them out of the way.
  14.  

Do not loosen or disconnect the air conditioning freon lines. Do not vent freon into the air.

  1. On the transmission, remove the speed sensor without disconnecting the hydraulic hoses. Disconnect the wiring and secure the unit out of the way.
  2.  
  3. Disconnect the transmission cooler hoses, upper and lower radiator hoses and the fan wiring. Remove the 2 upper brackets to remove the radiator assembly.
  4.  
  5. If equipped with an automatic transmission, remove the small torque converter cover. Rotate the crankshaft as required to remove the torque converter-to-drive plate bolts.
  6.  
  7. To disconnect the halfshafts, the lower damper fork and ball joint must be disconnected, allowing the steering knuckle to move away from the transaxle.
    1. With the front wheels removed, remove the damper fork nut and pinch bolt. Remove the damper fork from the lower arm.
    2.  
    3. Remove the lower ball joint castle nut press the ball joint out of the lower arm using a suitable puller, with the puller jaws grasping the lower arm.
    4.  
    5. Carefully pry the inner CV-joint away from the transaxle to force the set ring at the inner end past the groove.
    6.  
    7. Pull the inboard CV-joint, not the halfshaft, and remove the CV-joint out of the intermediate shaft.
    8.  

  8.  

Do not pull on the halfshaft, as the CV-joint may come apart. Use care when prying out the assembly and pull it straight to avoid damaging the intermediate shaft seals.

  1. Remove the oxygen sensor from the exhaust system and remove the front exhaust pipe.
  2.  
  3. If equipped with an automatic transmission, make sure the selector is in P . On manual transmission, put the selector into first gear.
  4.  
  5. On the lower left side of transmission housing, pry out the extension shaft cover and remove the 33mm sealing cap.
  6.  
  7. Use the extension shaft puller, tool no. 07LAC PW50100 to disengage the extension shaft from the differential. Remove the shaft.
  8.  
  9. Attach a lifting hoist to the engine lifting points and remove the upper engine-to-transmission bolts. Don't lose the 26mm spacer shim that is on the bolt near the differential.
  10.  
  11. Temporarily remove the left transmission mount.
  12.  



Click image to see an enlarged view

Fig. Fig. 12: Engine mount location and torque specifications-Vigor



Click image to see an enlarged view

Fig. Fig. 13: Additional engine mounting torque specifications-Vigor

  1. Remove the left front engine mount nut and stopper bolt. Remove the right front mount nut.
  2.  
  3. Remove the mid mounts. On automatic transmissions, there is a spacer between the mounts.
  4.  
  5. Support the transmission with a jack and remove the lower engine-to-transmission bolts. Separate the engine from the transmission and begin lifting the engine out. Make sure all hoses, wires and cables are disconnected before raising the engine all the way out.
  6.  
  7. After removing the engine, install the transmission mid mounts.
  8.  

To install:
  1. Before fitting the engine into place, make sure the pinion shaft in the differential is packed with high temperature molybdenum grease. Grease the extension shaft in the transmission and make sure it will not interfere with engine installation.
  2.  
  3. Support the transmission and remove the mid mounts. Carefully fit the engine into place and start the upper engine-to-transmission bolts. Slowly tighten 2 bolts on opposite sides just enough to draw the engine and transmission together. Install all the remaining bolts except for the differential-to-transmission housing bolt that had the spacer. Do not fully tighten the bolts yet.
  4.  
  5. If either the engine, transmission or differential is being replaced, the space between the differential and transmission housings must be measured and the correct shim installed. Shims are available in increments of 0.004 in. (0.1mm). Measure the space between the housings with a feeler gauge. Install the largest shim possible that does not exceed the measurement. If the wrong shim is installed, the differential or transmission housing could be cracked.
  6.  
  7. With the proper shim installed, torque the bolts to 54 ft. lbs. (75 Nm).
  8.  
  9. Loosely install the nuts and bolts for all the mounts and set the engine into place. Remove the lifting equipment.
  10.  
  11. Check the illustration and tighten the mounting nuts and bolts in the sequence shown to the correct torque. This is important for minimizing engine vibration and premature mount failure.
  12.  
  13. With the engine and transmission secure, grease the spline on the extension shaft and push it into place. Make sure the set ring clicks firmly into place. Coat the threads of the 33mm sealing cap with a sealing compound, install the cap and torque it to 58 ft. lbs. (80 Nm). Install the cover.
  14.  
  15. On an automatic transmission, install the torque converter-to-drive plate bolts and torque to 9 ft. lbs. (12 Nm). Do not over torque these bolts or the plate will distort. Install the cover.
  16.  
  17. Install the exhaust pipe with new self locking nuts and gaskets. Torque the nuts to 25 ft. lbs. (34 Nm).
  18.  
  19. Fit new set rings to the inner CV-joints. Press the joints into the differential and make sure the set ring snaps into place.
  20.  
  21. Connect the ball joint and damper fork. Torque the ball joint nut to 43 ft. lbs. (60 Nm) and install a new cotter pin.
  22.  
  23. Install the radiator assembly and connect the wiring and hoses.
  24.  
  25. Install the speed sensor, air conditioning compressor, power steering pump and alternator. Install and adjust the belts.
  26.  
  27. Before installing the distributor, check the condition of the O-rings on the collar.
  28.  
  29. Connect all remaining hoses, wires and control cables and adjust as required. Check the wiring carefully before connecting the battery.
  30.  
  31. After the engine is running, turn the heater control to full warm and bleed the cooling system.
  32.  

 
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