GM Prizm/Nova 1985-1993 Repair Guide

Engine

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REMOVAL & INSTALLATION



1985-88 VIN Code 4 Engine

All wires and hoses should be labeled at the time of removal. The amount of time saved during reassembly makes the extra effort well worthwhile.

  1. Disconnect the negative battery cable.
  2.  
  3. Drain the cooling system and save the coolant for reuse.
  4.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Drain the engine oil and the transmission oil.
  2.  


CAUTION
Used motor oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle oil on a daily basis, it is wise to thoroughly wash your hands with soap and water immediately after handling used motor oil.

  1. With the help of an assistant, remove the hood from the car. Be careful not to damage the paint finish.
  2.  
  3. Remove the air cleaner assembly from the carburetor.
  4.  
  5. Disconnect the upper radiator hose from the engine and remove the overflow hose.
  6.  
  7. Remove the coolant hose at the cylinder head rear coolant pipe and remove the coolant hose at the thermostat housing.
  8.  
  9. Remove the fuel hoses from the fuel pump.
  10.  
  11. Loosen the adjustor(s) and remove the alternator belt, the power steering and/or air conditioning drive belts depending on equipment.
  12.  
  13. Label and remove all wiring running to the motor. Be careful when unhooking wiring connectors; many have locking devices which must be released.
  14.  
  15. Label and disconnect vacuum hoses. Make sure your labels contain accurate information for reconnecting both ends of the hose. Make sure the labels will stay put on the hoses.
  16.  
  17. Disconnect the wiring at the transaxle.
  18.  
  19. Disconnect the speedometer cable at the transaxle.
  20.  
  21. Safely elevate and support the vehicle on jackstands.
  22.  
  23. Disconnect the exhaust pipe from the manifold. Be ready to deal with rusty hardware.
  24.  
  25. Disconnect the air hose at the converter pipe, if so equipped.
  26.  
  27. Loosen and remove the transaxle cooler lines at the radiator.
  28.  
  29. Remove the left and right undercovers (splash shields) under the car.
  30.  
  31. If so equipped, remove the power steering pump from its mounts and lay it aside. Leave the hoses attached. The pump may be hung on a piece of stiff wire to be kept out of the way.
  32.  
  33. If so equipped, remove the air conditioning compressor from its mounts and position out of the way. DO NOT loosen any hoses or fittings - simply move the compressor out of the way. It may be hung from a piece of stiff wire to be kept out of the way.
  34.  
  35. Disconnect the cable and bracket from the transaxle.
  36.  
  37. Disconnect the steering knuckles at the lower control arms.
  38.  
  39. Have an assistant step on the brake pedal while you loosen the nuts and bolts holding the driveshafts to the transaxle. Let the disconnected shafts hang down clear of the transaxle.
  40.  
  41. Remove the flywheel cover. If equipped with an automatic transmission, remove the flexplate-to-torque converter bolts.
  42.  
  43. Disconnect the front and rear mounts at the crossmember by first removing the 2 bolt covers and removing the 2 bolts at each mount. Remove the center crossmember under the engine.
  44.  
  45. Remove the clip and washer holding the shift cable; disconnect the cable at the outer shift lever or outer selector lever.
  46.  
  47. Lower the vehicle to the ground. Remove the radiator and fan assembly.
  48.  
  49. Install the engine hoist to the lifting bracket on the engine. Keep the wiring harness in front of the chain. Draw tension on the hoist enough to support the engine but no more. Double check the hoist attachments before proceeding.
  50.  
  51. Remove the through bolt to the right side engine mount.
  52.  
  53. Remove the left side transaxle mount bolt and remove the mount.
  54.  
  55. Lift the engine and transaxle assembly out of the engine compartment, proceeding slowly and watching for any interference. Pay particular attention to not damage the right side engine mount, the power steering housing and the neutral safety switch. Make sure wiring, hoses and cables are clear of the engine.
  56.  
  57. Support the engine assembly on a suitable stand; do not allow it to remain on the hoist for any length of time.
  58.  

To install:
  1. Lower the engine and transaxle into the car, paying attention to clearance and proper position.
  2.  
  3. Install the left side transaxle mount and its bolt.
  4.  
  5. Install and tighten the right side through bolt for the motor mount.
  6.  
  7. When the engine is securely mounted within the car, the lifting devices may be removed. Replace the radiator and fan assembly.
  8.  
  9. Safely elevate and support the vehicle on jackstands.
  10.  
  11. Install the center crossmember and connect the shift cable.
  12.  
  13. Connect the front and rear mountings for the crossmember and reinstall the bolt covers.
  14.  
  15. Install the flywheel-to-torque converter bolts. Tighten them to the final specification in 3 steps: first, all to 20 ft. lbs; next, all to 40 ft. lbs. and finally all to 58 ft. lbs.
  16.  
  17. Replace the flywheel cover.
  18.  
  19. Connect the driveshafts to the transaxle; correct tightness is 27 ft. lbs.
  20.  
  21. Reconnect the steering knuckles to the lower control arms.
  22.  
  23. Reattach the cable and bracket to the transaxle.
  24.  
  25. Depending on equipment, reinstall the power steering pump and/or the air conditioning compressor. Tighten the mounting bolts enough to hold the unit in place but no more; the belts will be installed later.
  26.  
  27. Install the left and right splash shields (under covers).
  28.  
  29. Reconnect the transmission cooler lines to the radiator and connect the air hose at the converter pipe.
  30.  
  31. Connect the exhaust pipe to the manifold and tighten the bolts to 46 ft. lbs.
  32.  
  33. Lower the vehicle to the ground; reconnect the speedometer cable at the transaxle.
  34.  
  35. Paying close attention to proper routing and labeling, connect the wiring and vacuum hoses to the engine.
  36.  
  37. Install the drive belts (alternator, power steering and air conditioning) and make sure the belts are properly seated on the pulleys. Adjust the belts to the correct tension and tighten the bolts.
  38.  
  39. Connect the fuel hoses at the fuel pump. Use new clamps if necessary.
  40.  
  41. Attach the coolant hoses: at the thermostat housing, at the cylinder head rear pipe, at the overflow, and at the outlet for the upper hose. Insure that the hoses are firmly over the ports; use new clamps wherever needed.
  42.  
  43. Install the air cleaner assembly onto the carburetor.
  44.  
  45. Have an assistant help reinstall the hood. Make sure its is properly adjusted and secure.
  46.  
  47. Refill the transmission with the proper fluid.
  48.  
  49. Refill the engine oil to the proper level.
  50.  
  51. Refill the engine coolant with the proper amount of fluid.
  52.  
  53. Double check all installation items, paying particular attention to loose hoses or hanging wires, untightened nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
  54.  

1988 VIN Code 5 Engine

See Figures 1 and 2

All wires and hoses should be labeled at the time of removal. The amount of time saved during reassembly makes the extra effort well worthwhile.

  1. Disconnect the negative battery cable.
  2.  
  3. With a helper remove the hood from the car. Use care not to damage the paint finish on the bodywork.
  4.  
  5. Drain the engine oil.
  6.  


CAUTION
Used motor oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle oil on a daily basis, it is wise to thoroughly wash your hands with soap and water immediately after handling used motor oil.

  1. Drain the cooling system. Save the coolant for reuse.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Drain the transaxle oil.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Remove the coolant reservoir tank and remove the PCV hose.
  6.  
  7. Remove the heater hoses from the water inlet housing.
  8.  
  9. Disconnect the fuel inlet hose from the fuel filter.
  10.  


CAUTION
The fuel system is under pressure. Release pressure slowly and contain spillage. Observe no smoking/no open flame precautions. Have a Class B-C (dry powder) fire extinguisher within arm's reach at all times.

  1. Disconnect the heater and air hoses from the air valve.
  2.  
  3. Remove the fuel return hose from the pressure regulator.
  4.  
  5. If equipped with a manual transaxle, remove the slave cylinder from the housing. Loosen the mounting bolts and move the cylinder out of the way but do not loosen or remove the fluid hose running to the cylinder.
  6.  
  7. Disconnect the vacuum hose running to the charcoal cannister.
  8.  
  9. Disconnect the shift control cable, the speedometer cable (at the trans) and the accelerator cable (at the throttle body).
  10.  
  11. If the car has cruise control, disconnect the cables. Remove the cruise control actuator by:
    1. Disconnecting the vacuum hose,
    2.  
    3. Removing the cover and the 3 bolts,
    4.  
    5. Disconnecting the actuator connector and removing the actuator.
    6.  

  12.  
  13. Remove the ignition coil.
  14.  
  15. Remove the main engine wiring harness in the following steps:
    1. Inside the car, remove the right side cowl (kick) panel.
    2.  
    3. Disconnect the connectors at junction block 4.
    4.  
    5. Remove the cover over the Electronic Control Module (ECM) and carefully disconnect the ECM plugs.
    6.  
    7. Pull the main wiring harness into the engine compartment.
    8.  

  16.  
  17. Disconnect the wiring at the number 2 junction block in the engine compartment.
  18.  
  19. Remove the engine and transaxle ground straps.
  20.  
  21. Disconnect the washer change valve connector.
  22.  
  23. Remove the wiring at the cruise control vacuum pump connector and the vacuum switch connector.
  24.  
  25. Remove the hose from the brake vacuum booster.
  26.  
  27. Depending on equipment, remove the air conditioning compressor and/or the power steering pump. Note that the units are to be removed from their mounts and placed out of the way - hoses and lines DO NOT disconnect from the units.
    1. Remove the power steering pump pulley nut.
    2.  
    3. Loosen the idler pulley adjusting bolt and pulley bolt.
    4.  
    5. Remove the 4 compressor mounting bolts.
    6.  
    7. Move the compressor aside and suspend it from stiff wire out of the way.
    8.  
    9. Loosen the compressor bracket bolts.
    10.  
    11. Disconnect the oil pressure connector.
    12.  
    13. Loosen the power steering pump lock bolts and pivot bolts.
    14.  
    15. Remove the pump and its bracket; suspend it out of the way with a piece of stiff wire.
    16.  

  28.  
  29. Safely elevate the vehicle and support on jackstands. Double check the stands and make sure the vehicle is solidly supported.
  30.  
  31. Remove the splash shields under the car.
  32.  
  33. Disconnect the oil cooler hoses.
  34.  
  35. Disconnect the exhaust pipe from the exhaust manifold.
  36.  
  37. Carefully disconnect the wiring from the oxygen sensor.
  38.  
  39. Remove the cover under the flywheel.
  40.  
  41. Remove the front and rear motor mounts from the center crossmember.
  42.  



Click image to see an enlarged view

Fig. Fig. 1: Removing the engine mounts from the crossmember - 1988 VIN code 5 engine

  1. Remove the center crossmember.
  2.  
  3. Disconnect the right side control arm at the steering knuckle.
  4.  
  5. Disconnect the driveshafts from the transaxle.
  6.  
  7. Lower the vehicle to the ground. Install the engine hoist to the lifting bracket on the engine. Hang the engine wires and hoses on the lift chain. Take tension on the hoist sufficient to support the motor; double check all hoist attaching points.
  8.  
  9. Disconnect the right side engine mount by removing the bolt.
  10.  
  11. Disconnect the left side motor mount from the transaxle bracket.
  12.  



Click image to see an enlarged view

Fig. Fig. 2: Removing the left side engine mount at the transaxle - 1988 VIN code 5 engine

  1. Lift the engine and transaxle from the vehicle.
  2.  


WARNING
Be careful to avoid hitting the steering box and the throttle position sensor.

  1. Support the engine assembly on a suitable stand; do not allow it to remain on the hoist for any length of time.
  2.  
  3. Disconnect the radiator fan temperature switch connector.
  4.  
  5. Disconnect the start injector time switch.
  6.  
  7. Remove the vacuum hoses from the Bimetal Vacuum Switching Valves (BVSV).
  8.  
  9. Remove the hoses from the water bypass valves and remove the water inlet housing assembly.
  10.  
  11. Label and remove the wiring connectors from the reverse switch, the water temperature sensor, and the water temperature switch. On cars with automatic transmissions remove the wiring to the neutral safety switch and the transaxle solenoid.
  12.  
  13. If equipped with automatic transmission, remove the 6 torque converter - to-flexplate bolts.
  14.  
  15. Remove the starter along with its cable and connector.
  16.  
  17. Support the transaxle, remove the retaining bolts in the case and remove the transaxle from the engine. Pull the unit straight off the engine; do not allow it to hang partially removed on the shaft. Keep the automatic transaxle level; if it tilts forward the converter may fall off.
  18.  

To install:
  1. Before reinstalling the engine in the car, several components must be reattached or connected. Install the transaxle to the engine; tighten the 12mm bolts to 47 ft. lbs and the 10mm bolts to 34 ft. lbs.
  2.  
  3. Install the starter, its cable and connector. Tighten the mounting bolts to 29 ft. lbs.
  4.  
  5. Install the 6 torque converter-to-flexplate bolts on automatic transaxles. Tighten the bolts to 20 ft. lbs
  6.  
  7. Attach the wiring to the reverse light switch, the water temperature sensor and the water temperature switch.
  8.  
  9. Connect the hoses to the water bypass pipes and the wiring to the start injector time switch and the radiator fan temperature switch.
  10.  
  11. On automatic transaxle vehicles, connect the wiring to the neutral safety switch and the transmission solenoid.
  12.  
  13. Reinstall the water inlet housing assembly and connect the vacuum hoses to the BVSVs.
  14.  
  15. Attach the lifting mechanism to the engine; drape the hoses and wires on the chain.
  16.  
  17. Lower the engine and transaxle into place in the vehicle. Be careful not to hit the power steering gear housing or the throttle position sensor.
  18.  
  19. Install the right motor mount and through bolt; tighten it to 58 ft. lbs.
  20.  
  21. Install the left mount and attach it to the transaxle bracket. When the engine is securely mounted in the car, the lifting equipment may be removed.
  22.  
  23. Safely elevate and support the vehicle on jackstands.
  24.  
  25. Connect the driveshafts to the transaxle. Tighten the bolts to 27 ft. lbs.
  26.  
  27. Attach the right side control arm to the steering knuckle and tighten the bolts and nuts to 47 ft. lbs.
  28.  
  29. Replace the cover under the flywheel.
  30.  
  31. Install the engine mount center crossmember, tightening the bolts to 29 ft. lbs.
  32.  
  33. Install the front and rear mounts onto the crossmember. Tighten the mount bolts to 35 ft.lbs and the front and rear through bolts to 58 ft. lbs.
  34.  
  35. Using new gaskets and nuts, connect the exhaust pipe to the exhaust manifold; correct torque is 46 ft. lbs.
  36.  
  37. Connect the wiring to the oxygen sensor and attach the oil cooler lines.
  38.  
  39. Lower the vehicle from its stands to the ground.
  40.  
  41. Install the power steering pump and pulley with its bracket. Tighten the lock bolt and the pivot bolt.
  42.  
  43. Connect the wiring to the oil pressure unit.
  44.  
  45. Install the compressor bracket, the compressor and the belt. Tighten the pulley bolt on the power steering pump to 28 ft. lbs.
  46.  
  47. Install the drive belts and adjust them to the proper tension. Make certain each belt is properly fitted on its pulleys.
  48.  
  49. Connect the vacuum hose to the brake booster.
  50.  
  51. Install the wiring to the No. 2 junction block. Connect the cable from the starter to the positive battery terminal and connect the engine and transaxle ground straps. DO NOT connect the negative battery cable at this time.
  52.  
  53. Attach the connectors for the washer change valve, and, if equipped, the cruise control vacuum pump and vacuum switch.
  54.  
  55. Connect the main engine wiring harness by:
    1. Feeding the 2 connectors from the engine compartment back into the passenger compartment,
    2.  
    3. Connecting the ECM connector(s) and replacing the cover,
    4.  
    5. Connecting the wiring to the No. 4 junction block.
    6.  
    7. Replacing the right side kick panel.
    8.  

  56.  
  57. Reinstall the ignition coil.
  58.  
  59. If so, equipped install the cruise control actuator.
  60.  
  61. Connect or reinstall the cables for the accelerator, the cruise control, the speedometer and the shifter.
  62.  
  63. Install the vacuum hose to charcoal cannister.
  64.  
  65. On cars with manual transaxles, attach the clutch slave cylinder to the bell housing.
  66.  
  67. Attach the fuel return hose to the pressure regulator, the heater and air hoses to the air valve and the fuel hose to the fuel filter.
  68.  
  69. Connect the heater hoses to the water inlet housing.
  70.  
  71. Reinstall the PCV hose, the coolant reservoir and the air cleaner assembly.
  72.  
  73. Fill the transaxle with the correct amount of fresh oil, and fill the engine with fresh oil.
  74.  
  75. Fill the cooling system with the proper amount of fluid.
  76.  
  77. Double check all installation items, paying particular attention to loose hoses or hanging wires, untightened nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
  78.  
  79. Connect the negative battery cable.
  80.  
  81. Start the engine and allow it to approach normal operating temperature. Check carefully for leaks. Shut the engine off.
  82.  
  83. Elevate the front end of the car, support on jackstands and install the splash shields below the car.
  84.  
  85. Lower the car to the ground. With your helper, install the hood and adjust it for proper fit and latching.
  86.  

1989-90 VIN Code 6 Engine

See Figures 3, 4 and 5

  1. Remove the hood. Have a helper assist you and be careful not to damage the painted bodywork.
  2.  
  3. Disconnect the negative battery cable, then the positive battery cable and remove the battery.
  4.  
  5. Raise the vehicle and safely support it on jackstands.
  6.  
  7. Remove the left and right splash shields.
  8.  
  9. Drain the engine oil and the transmission oil.
  10.  


CAUTION
Used motor oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle oil on a daily basis, it is wise to thoroughly wash your hands with soap and water immediately after handling used motor oil.

  1. Drain the engine coolant and save it in closed containers for reuse.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

  1. Remove the air cleaner hose and the air cleaner assembly.
  2.  
  3. Remove the coolant reservoir. Remove the radiator and fan assembly.
  4.  
  5. Disconnect the accelerator cable and if equipped with automatic transaxle,the throttle cable.
  6.  
  7. Disconnect and remove the cruise control actuator.
  8.  
  9. Label and disconnect the main engine wiring harness from its related sensors and switches.
  10.  
  11. Remove the ground strap connector and its bolt. Disconnect the wiring to the vacuum sensor, the oxygen sensor and the air conditioning compressor.
  12.  
  13. Label and disconnect the brake booster vacuum hose, the power steering vacuum hose, the charcoal cannister vacuum hose and the vacuum switch vacuum hose.
  14.  
  15. Carefully disconnect the fuel inlet and return lines.
  16.  


CAUTION
The fuel system is under pressure. Release pressure slowly and contain spillage. Observe no smoking/no open flame precautions. Have a Class B-C (dry powder) fire extinguisher within arm's reach at all times.



Click image to see an enlarged view

Fig. Fig. 3: Fuel inlet line - 1989-90 VIN code 6 engine

  1. Disconnect the heater hoses.
  2.  
  3. Loosen the power steering pump mounting bolt and through bolt. Remove the drive belt.
  4.  
  5. Remove the 4 bolts holding the air conditioner compressor and remove the compressor. DO NOT loosen or remove any lines or hoses. Move the compressor out of the way and hang it from a piece of stiff wire.
  6.  
  7. Disconnect the speedometer cable from the transaxle.
  8.  
  9. On cars with manual transmissions, unbolt the clutch slave cylinder from the bell housing and move the cylinder out of the way. Don't disconnect any lines or hoses. Disconnect the shift control cables by removing the 2 clips, the washers and retainers.
  10.  
  11. On cars with automatic transmissions, remove the clip and retainer and separate the control cable from the shift lever.
  12.  
  13. Elevate the car and support it safely on jackstands.
  14.  
  15. Remove the 2 bolts from the exhaust pipe flange and separate the pipe from the exhaust manifold.
  16.  
  17. Remove the nuts and bolts and separate the driveshafts from the transaxle.
  18.  
  19. Remove the through bolt from the rear transaxle mount.
  20.  
  21. Remove the nuts from the center transaxle mount and the rear mount.
  22.  
  23. Lower the vehicle to the ground and attach the lifting equipment to the brackets on the engine. Take tension on the hoist line or chain just enough to support the motor but no more. Hang the engine wires and hoses on the chain or cable.
  24.  
  25. Remove the 3 exhaust hanger bracket nuts and the hanger. Remove the 2 center crossmember-to-main crossmember bolts. Remove the 3 center crossmember-to-radiator support bolts.
  26.  


CAUTION
Support the crossmembers with a jack or jackstands when loosening the bolts. The pieces are heavy and could fall on you.

  1. Remove the 8 crossmember-to-body bolts, then remove the 2 bolts holding the control arm brackets to the underbody. Remove the 2 center mount-to-transaxle bolts and remove the mount. Carefully lower the center mount and crossmember and remove from under the car.
  2.  
  3. At the left engine mount, remove the 3 bolts and the bracket, then remove the bolt, 2 nuts, through bolt and mounting. Remove the 3 bolts and the air cleaner bracket.
  4.  



Click image to see an enlarged view

Fig. Fig. 4: Removing the engine mount-to-bracket bolt - 1989-90 VIN code 6 engine



Click image to see an enlarged view

Fig. Fig. 5: Detail of the crossmember and center support - 1989-90 VIN code 5 & 6 engine

  1. Loosen and remove the 5 bolts and disconnect the mounting bracket from the transaxle bracket. Remove the through bolt and mounting.
  2.  
  3. Carefully and slowly raise the engine and transaxle assembly out of the car. Tilt the transaxle down to clear the right engine mount. Be careful not to hit the steering gear housing. Make sure the engine is clear of all wiring, lines and hoses.
  4.  
  5. Support the engine assembly on a suitable stand; do not allow it to remain on the hoist for any length of time.
  6.  
  7. With the engine properly supported, disconnect the reverse light switch and the neutral safety switch (automatic trans).
  8.  
  9. Remove the rear end cover plate.
  10.  
  11. For automatic transaxles, remove the 6 torque converter mounting bolts.
  12.  
  13. Remove the starter.
  14.  
  15. Support the transaxle, remove the retaining bolts in the case and remove the transaxle from the engine. Pull the unit straight off the engine; do not allow it to hang partially removed on the shaft. Keep the automatic transaxle level; if it tilts forward the converter may fall off.
  16.  

To install:
  1. Before reinstalling the engine in the car, several components must be reattached or connected. Install the transaxle to the engine; tighten the 12mm bolts to 47 ft. lbs and the 10mm bolts to 34 ft. lbs
  2.  
  3. Install the starter, its cable and connector. Tighten the mounting bolts to 29 ft. lbs.
  4.  
  5. Install the 6 torque converter-to-flexplate bolts on automatic transaxles. Tighten the bolts to 20 ft. lbs.
  6.  
  7. Install the rear cover plate and connect the wiring to the reverse light switch and the neutral safety switch (automatic trans.).
  8.  
  9. Attach the chain hoist or lift apparatus to the engine and lower it into the engine compartment. Before it is completely in position, attach the power steering pump and its through bolt to the motor.
  10.  

Tilt the transaxle downward and lower the engine to clear the left motor mount. As before, be careful not to hit the power steering housing (rack) or the throttle position sensor.

  1. Level the engine and align each mount with its bracket.
  2.  
  3. Install the right mounting insulator (bushing) to the engine bracket with the 2 nuts and bolt. Tighten the bolt temporarily.
  4.  
  5. Align the right insulator with the body bracket and install the through bolt and nut. Temporarily tighten the nut and bolt.
  6.  
  7. Align the left mounting insulator with the transaxle case bracket. Temporarily install the 3 bracket bolts.
  8.  
  9. With the engine held in place by these mounts, repeat steps 44, 45 and 46, tightening the bolts to the following tightness. Step 44: 38 ft. lbs.; step 45: 64 ft. lbs.; step 46: 35 ft. lbs.
  10.  
  11. Install the left sidemounting support with its 2 bolts; tighten them to 15 ft. lbs.
  12.  
  13. With the engine securely mounted in the car, the lifting equipment may be removed. Elevate the car and support it on jackstands.
  14.  
  15. Install the center mount to the transaxle with its 2 bolts and tighten them to 45 ft. lbs.
  16.  
  17. Position the center mount over the front and rear studs and start 2 nuts on the center mount only. Loosely install the 3 center support-to-radiator support bolts.
  18.  
  19. Loosely install the 2 front mount bolts. Raise the main crossmember into place over the rear studs and align all the underbody bolts.
  20.  
  21. Install the 2 rear mount nuts; leave them loose.
  22.  
  23. Loosely install the 8 underbody bolts, the lower control arm bracket bolts, the 2 center support-to-crossmember bolts and the exhaust hanger bracket and nuts.
  24.  
  25. With everything loose, but in place, make a second pass over all the nuts and bolts tightening them to the following specifications:

    Crossmember-to-underbody bolts: 152 ft. lbs.
     
    Lower control arm bracket-to-underbody bolts: 94 ft. lbs.
     
    Center support-to-radiator support: 45 ft. lbs.
     
    Center support-to-crossmember: 45 ft. lbs.
     
    Front, center and rear mount bolts: 45 ft. lbs.
     
    Exhaust hanger bracket nuts: 9 ft. lbs. (115 INCH lbs.)
     

  26.  
  27. Install the rear transaxle mount and tighten its bolt to 64 ft. lbs.
  28.  
  29. Install the nuts on the center transaxle mount and tighten them to 45 ft. lbs.
  30.  
  31. Reconnect the driveshafts to the transaxle.
  32.  
  33. Using a new gasket, connect the exhaust pipe to the manifold and install the exhaust pipe bolts, tightening them to 18 ft. lbs.
  34.  
  35. Lower the vehicle to the ground.
  36.  
  37. Either connect the control cables to the shift outer lever and selector lever and attach the control cables to manual transaxles or reconnect the control cable to the shift lever and install the clip and retainer on automatic transaxles. If equipped with manual transaxle, reattach the clutch slave cylinder to its mount.
  38.  
  39. Attach the speedometer cable to the transaxle.
  40.  
  41. Install the air conditioning compressor and drive belt if so equipped.
  42.  
  43. Install the power steering pump, pivot bolt and drive belt if so equipped. Adjust the belts to the correct tension.
  44.  
  45. Install the fuel inlet and outlet lines.
  46.  
  47. Connect the heater hoses. Make sure they are in the correct positions and that the clamps are in sound condition.
  48.  
  49. Connect the vacuum hoses to the vacuum switch, the charcoal canister, the vacuum sensor, the power steering and the brake booster.
  50.  
  51. Connect the wiring to the air conditioning, the oxygen sensor and the vacuum sensor.
  52.  
  53. Observing the labels made at the time of disassembly, reconnect the main engine harness to its sensors and switches. Work carefully and make sure each connector is properly matched and firmly seated.
  54.  
  55. Install the ground strap connector and its bolt; connect the wiring at the No. 2 junction block in the engine compartment.
  56.  
  57. Install the cruise control actuator if so equipped.
  58.  
  59. Connect the accelerator cable and throttle cable (automatic) to their brackets.
  60.  
  61. Install the radiator and cooling fan assembly. Install the overflow reservoir.
  62.  
  63. Install the air cleaner assembly and the air intake hose.
  64.  
  65. Install the battery. Connect the positive cable to the starter terminal, then to the battery. DO NOT connect the negative battery cable at this time.
  66.  
  67. Fill the transmission with the correct amount of fresh fluid.
  68.  
  69. Refill the engine coolant.
  70.  
  71. Fill the engine with the correct amount of fresh oil.
  72.  
  73. Double check all installation items, paying particular attention to loose hoses or hanging wires, untightened nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
  74.  
  75. Connect the negative battery cable. Start the engine and allow it to idle. As the engine warms up, shift the automatic transmission into each gear range allowing it to engage momentarily. After each gear has been selected, put the shifter in PARK and check the transmission fluid level.
  76.  
  77. Shut the engine off and check the engine area carefully for leaks, particularly around any line or hose which was disconnected during removal.
  78.  
  79. Elevate and support the front end of the car on jackstands. Replace the left and right splash shields and lower the vehicle.
  80.  
  81. With the help of an assistant, reinstall the hood. Adjust the hood for proper fit and latching.
  82.  

1990 VIN Code 5 Engine 1991-92 All Engines

See Figure 6

  1. Disconnect the negative terminal from the battery.
  2.  
  3. Using a scratch awl, scribe the hood hinge-to-hood outline. Disconnect the windshield washer fluid lines from the hood. Remove the 4 hood hinge bolts (2 on each side) disengaging the hood from the hinge. Using an assistant remove the hood.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Remove the left and right stone shields.
  10.  
  11. Drain the engine oil and the cooling system.
  12.  
  13. Drain the transaxle fluid. Lower the vehicle.
  14.  
  15. Remove the air cleaner hose and air cleaner assembly. Remove the radiator, cooling fan and cooling overflow reservoir.
  16.  
  17. Disconnect the accelerator cable and throttle cable from the bracket.
  18.  
  19. Remove the cruise control actuator.
  20.  
  21. Disconnect and tag all electrical component connectors.
  22.  
  23. Disconnect and tag all the necessary vacuum lines.
  24.  
  25. Remove the fuel inlet and outlet lines.
  26.  
  27. Remove the heater hoses from the engine.
  28.  
  29. Remove the power steering pump and bracket from the engine and set it off to the side. Leave the power steering hydraulic lines hook up to the pump.
  30.  
  31. Remove the air conditioning compressor and bracket bolts from the engine and set it off to the side. Leave the freon lines hooked up to the compressor.
  32.  
  33. Remove the speedometer cable from the transaxle.
  34.  
  35. Disconnect the clutch release cylinder without disconnecting the line and hose (manual transaxles only).
  36.  
  37. On the manual transaxle models, disconnect the transaxle control cables by removing the 2 clips, washers and retainers. Disconnect the control cables from the shift outer lever and select outer lever.
  38.  
  39. Disconnect the control cable from the shift lever (automatic transaxle only).
  40.  
  41. Raise and safely support the vehicle.
  42.  
  43. Disconnect the front exhaust pipe from the exhaust manifold.
  44.  
  45. Remove the transaxle mounts. Lower the vehicle.
  46.  
  47. Remove the engine mounts.
  48.  
  49. Attach a suitable chain hoist to the lifting device on the engine. Slowly lift the engine/transaxle assembly out of the vehicle and place it in a suitable engine stand.
  50.  

To install:
  1. Attach a suitable chain hoist to the lifting device on the engine. Slowly lift the engine/transaxle assembly into the vehicle.
  2.  
  3. Tilt the transaxle downward to clear the left mount.
  4.  
  5. Raise and safely support the vehicle. Install the engine and transaxle mounts.
  6.  
  7. Install the drive axles.
  8.  
  9. Install the exhaust pipe to the exhaust manifold.
  10.  
  11. Install the right and left and stone shields. Lower the vehicle.
  12.  
  13. Install the control cable to the shift lever (automatic transaxle).
  14.  
  15. On vehicles equipped with manual transaxles, install the control cables to the shift outer lever and select outer lever. Install the clutch release cylinder.
  16.  
  17. Install the air conditioner compressor bracket, compressor and bolts.
  18.  
  19. Install the power steering pump and bracket to the engine.
  20.  
  21. Install the heater hoses to the engine.
  22.  
  23. Install the fuel inlet and outlet lines.
  24.  
  25. Reconnect the disconnected vacuum lines.
  26.  
  27. Reconnect the disconnected electrical connectors.
  28.  
  29. Install the cruise control actuator.
  30.  
  31. Install the accelerator and throttle cable to the bracket.
  32.  
  33. Install the radiator, cooling fan and overflow reservoir. Refill the cooling system.
  34.  
  35. Install the air cleaner hose and air cleaner assembly.
  36.  
  37. Refill the transaxle.
  38.  
  39. Refill the engine with the recommended oil.
  40.  
  41. Reconnect the battery.
  42.  
  43. Install the hood assembly.
  44.  
  45. Start the engine and check for leakage of any kind. Make all necessary repairs and adjustments.
  46.  
  47. Torque the center transaxle mount-to-center crossmember nuts 45 ft. lbs. (61 Nm)
  48.  
  49. Torque the rear transaxle mount-to-main crossmember nuts 45 ft. lbs. (61 Nm).
  50.  
  51. Torque the right engine mount through bolt 64 ft. lbs. (87 Nm).
  52.  
  53. Torque the right engine mount support bolts 35 ft. lbs. (47 Nm).
  54.  
  55. Torque the right engine mount support bolts 35 ft. lbs. (47 Nm).
  56.  
  57. Torque the engine mount-to-engine bracket nuts 45 ft. lbs. (61 Nm).
  58.  
  59. Torque the engine mount-to-bracket bolt 45 ft. lbs. (61 Nm).
  60.  
  61. On vehicles equipped with an automatic transaxle, torque the flywheel retaining bolts to 47 ft. lbs. (64 Nm).
  62.  
  63. On vehicles equipped with a manual transaxle, torque the flywheel retaining bolts to 58 ft. lbs. (78 Nm).
  64.  



Click image to see an enlarged view

Fig. Fig. 6: Engine alignment with mounts - 1991-92

1993
  1. Disconnect the negative terminal from the battery.
  2.  
  3. Using a scratch awl, scribe the hood hinge-to-hood outline. Disconnect the windshield washer fluid lines from the hood. Remove the 4 hood hinge bolts (2 on each side) disengaging the hood from the hinge. Using an assistant remove the hood.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Remove the 12 bolts and remove the left and right stone shields.
  10.  
  11. Drain the engine oil and the cooling system.
  12.  
  13. Drain the transaxle fluid. Lower the vehicle.
  14.  
  15. Disconnect the accelerator cable from the accelerator bracket.
  16.  
  17. Disconnect the accelerator cable and kickdown cable (with auto. trans.) from the accelerator bracket.
  18.  
  19. Remove the radiator and cooling fan assembly.
  20.  
  21. Disconnect and label the following electrical connectors:

    Throttle position (TP) sensor.
     
    Idle air control (IAC) valve.
     
    Throttle opener solenoid vacuum (TP SV) valve.
     
    Manifold absolute pressure (MAP) sensor.
     
    Intake air temperature (IAT) sensor.
     
    Engine coolant temperature (ECT) sensor.
     
    ECT sensor sending unit.
     
    Data link connector (DLC).
     
    A/C ECT switch (A/C equipped vehicles only).
     
    Exhaust gas recirculation (EGR) temperature sensor (California specification vehicles).
     
    Wiring harness from retaining clamps on fenders.
     
    Engine ground wires from intake manifold, right hand fender and left hand fender.
     

  22.  
  23. Disconnect and tag the following vacuum hoses:

    TP SV Valve.
     
    Solenoid purge (SP) valve.
     
    EGR valve.
     

  24.  
  25. Disconnect the hose clamp and air hose from the air cleaner(ACL).
  26.  
  27. Disconnect the 4 clips and the air cleaner upper case.
  28.  
  29. Remove air the cleaner element from the air cleaner.
  30.  
  31. Remove the air cleaner retaining harness, the 3 bolts and the air cleaner lower case.
  32.  
  33. Remove the battery.
  34.  
  35. Remove 2 bolts and coolant reservoir support bracket.
  36.  
  37. Remove the 1 bolt, and the windshield washer reservoir from the vehicle; disconnecting the electrical connector and hose.
  38.  
  39. Pry off the cruise control actuator cover (if equipped).
  40.  
  41. Remove the 3 bolts and the cruise control actuator.
  42.  
  43. Remove the 2 hose clamps and heater hose from the thermostat housing and coolant inlet pipe.
  44.  
  45. Disconnect the fuel feed pipe from fuel rail and intake manifold.
  46.  
  47. Disconnect the fuel return hose from fuel pressure (FPR) regulator.
  48.  
  49. Remove the clutch release cylinder (manual transaxle equipped vehicles).
  50.  
  51. Disconnect the transaxle control cable(s) from transaxle.
  52.  
  53. Remove the scuff plates from left and right side.
  54.  
  55. Remove the shift lever knob (manual transaxle equipped vehicles).
  56.  
  57. Remove the knee bolster, glove box door, instrument panel trim bezel, front and rear console and left hand cowl side trim panel.
  58.  
  59. Remove the radio.
  60.  
  61. Disconnect the 3 engine control module (ECM) connectors.
  62.  
  63. Disconnect the cowl wire harness connector.
  64.  
  65. Pull the engine wire harness from the cowl panel.
  66.  
  67. Remove the A/C compressor, if equipped, without disconnecting hoses. Remove drive belt and relocate compressor, temporarily suspending it from the radiator support bracket.
  68.  
  69. Remove the power steering pump, if equipped.
  70.  
  71. Raise and safely support the vehicle.
  72.  
  73. Remove the front pipe (Federal specification vehicles).
    1. Disconnect the Oxygen (O2) sensor.
    2.  
    3. Remove the 2 front pipe to support bolts.
    4.  
    5. Remove the 2 front pipe to exhaust manifold nuts and bolts.
    6.  
    7. Remove the 2 front pipe mount nuts and front pipe with 2 gaskets from the vehicle.
    8.  

  74.  
  75. Remove the front pipe (California specification vehicles).
    1. Disconnect the Oxygen (O2) and sub-Oxygen (O2) sensor connectors.
    2.  
    3. Remove the 2 front pipe to warm up 3-way catalytic converter (WU-TWC) bolts and nuts.
    4.  
    5. Remove the 2 front pipe to support bolts.
    6.  
    7. Remove the 2 front pipe to exhaust manifold nuts.
    8.  

  76.  
  77. Remove the left and right drive axles from the transaxle.
  78.  

It is not necessary to remove the drive axle from the steering knuckle for engine or transaxle removal.

  1. Lower the vehicle.
  2.  
  3. Attach an engine hoist.
  4.  
  5. Disconnect the transaxle mounts.
  6.  
  7. Disconnect the engine mounts.
  8.  
  9. Make sure all the wires and hoses are disconnected and remove the engine and transaxle from the vehicle, ensuring clearance on all sides.
  10.  

To install:
  1. Install the engine and transaxle to the vehicle, ensuring clearance on all sides.
  2.  
  3. Connect the transaxle mounts.

    Tighten the 2 mounting bolts to 45 ft. lbs. (61 Nm).
     
    Tighten the mount through bolt to 64 ft. lbs. (87 Nm).
     

  4.  
  5. Connect the engine mounts and tighten the through bolts to 47 ft. lbs. (64 Nm).
  6.  
  7. Remove the engine hoist.
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Install the left and right drive axles to the transaxle.
  12.  
  13. Install the front pipe (Federal specification vehicles).
    1. Install the 2 front pipe mount nuts and the front pipe with the 2 gaskets to the vehicle.
    2.  
    3. Install the 2 front pipe to exhaust manifold nuts and bolts but do not fully tighten at this time.
    4.  
    5. Connect the Oxygen (O2) sensor.
    6.  
    7. Install the 2 front pipe to support bolts.
    8.  
    9. Tighten all bolts as follows:

      Front pipe to exhaust manifold nuts and bolts to 46 ft. lbs. (62 Nm).
       
      Front pipe to support bolts to 14 ft. lbs. (19 Nm).
       

    10.  

  14.  
  15. Install the front pipe (California specification vehicles):
    1. Install 2 new gaskets to the front pipes.
    2.  
    3. Install the front pipe to TWC, secure with the bolts and nuts, but do not fully tighten at this time.
    4.  
    5. Connect the Oxygen (O2) and sub-Oxygen (O2) sensor connectors.
    6.  
    7. Install the 2 front pipe to warm up 3-way catalytic converter (WU-TWC) bolts and nuts, but do not tighten at this time.
    8.  
    9. Install the 2 front pipe to support bolts.
    10.  
    11. Tighten all bolts as follows:

      Front pipe to WU-TWC nuts and bolts to 46 ft. lbs. (62 Nm).
       
      Front pipe to TWC bolts and nuts to 32 ft. lbs. (43 Nm).
       
      Front pipe to support bolts to 14 ft. lbs. (19 Nm).
       

    12.  

  16.  
  17. Lower the vehicle.
  18.  
  19. Install the power steering pump (if equipped).
  20.  
  21. Install the A/C compressor, if equipped.
  22.  
  23. Push the engine wire harness through the cowl panel and connect the connector.
  24.  
  25. Connect the 3 engine control module (ECM) connectors.
  26.  
  27. Install the radio.
  28.  
  29. Install the knee bolster, glove box door, instrument panel trim bezel, front and rear console and left hand cowl side trim panel.
  30.  
  31. Install the scuff plates to the left and right side.
  32.  
  33. Install the shift lever knob (manual transaxle equipped vehicles).
  34.  
  35. Connect the transaxle control cable(s) from transaxle.
  36.  
  37. Install the clutch release cylinder (manual transaxle equipped vehicles).
  38.  
  39. Connect the fuel feed pipe to fuel rail and intake manifold and tighten to 22 ft. lbs. (29 Nm).
  40.  
  41. Connect the fuel return hose to the fuel pressure (FPR) regulator.
  42.  
  43. Install the 2 hose clamps and heater hose to the thermostat housing and coolant inlet pipe.
  44.  
  45. Install the 3 bolts and the cruise control actuator. Tighten to 19 ft. lbs. (25 Nm)
  46.  
  47. Install the cruise control actuator cover.
  48.  
  49. Install the 1 bolt, and the windshield washer reservoir to the vehicle; connecting the electrical connector and hose.
  50.  
  51. Install the 2 bolts and coolant reservoir support bracket.
  52.  
  53. Install the battery.
  54.  
  55. Install the air cleaner retaining harness, the 3 bolts and the air cleaner lower case. Install a new element.
  56.  
  57. Connect the 4 clips and the air cleaner upper case.
  58.  
  59. Connect the hose clamp and air hose to the air cleaner(ACL).
  60.  
  61. Install the radiator and cooling fan assembly.
  62.  
  63. Connect the following electrical connectors:

    Throttle position (TP) sensor.
     
    Idle air control (IAC) valve.
     
    Throttle opener solenoid vacuum (TP SV) valve.
     
    Manifold absolute pressure (MAP) sensor.
     
    Intake air temperature (IAT) sensor.
     
    Engine coolant temperature (ECT) sensor.
     
    ECT sensor sending unit.
     
    Data link connector (DLC).
     
    A/C ECT switch (A/C equipped vehicles only).
     
    Exhaust gas recirculation (EGR) temperature sensor (California specification vehicles).
     
    Wiring harness from retaining clamps on fenders.
     
    Engine ground wires from intake manifold, right hand fender and left hand fender.
     

  64.  
  65. Connect the following vacuum hoses:

    TP SV Valve.
     
    Solenoid purge (SP) valve.
     
    EGR valve.
     

  66.  
  67. Connect the accelerator cable to the accelerator bracket.
  68.  
  69. Connect the accelerator cable and kickdown cable (with auto. trans.) to the accelerator bracket.
  70.  
  71. Fill the transaxle fluid.
  72.  
  73. Install the 12 bolts and the left and right stone shields.
  74.  
  75. Fill the engine oil and the cooling system.
  76.  
  77. Install the oil drain plug and gasket.
  78.  
  79. Lower the vehicle.
  80.  
  81. Connect the battery terminals to the battery.
  82.  
  83. Install the 4 hood hinge bolts (2 on each side) engaging the hood to the hinge. Use an assistant to install the hood.
  84.  
  85. Fill the engine oil and the cooling system.
  86.  

 
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