I30 1996-1997

Engine

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Removal & Installation



It is recommended the engine and transaxle be removed as a single unit. If necessary, the units may be separated after removal.


NOTE
The engine and transaxle assembly must be removed from the under side of the vehicle.

  1. Matchmark the hood hinge relationship and remove the hood.
  2.  
  3. Release the fuel system pressure and disconnect the negative battery cable.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Drain the coolant from the cylinder block and the radiator. Drain the crankcase and the automatic transaxle, if equipped.
  8.  
  9. Remove the air cleaner, the air intake tube, the air flow meter and disconnect the throttle linkage.
  10.  
  11. Disconnect and/or remove the following:
    CAUTION
    The fuel injection system remains under pressure after the engine has been turned OFF. Properly relieve the fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.



    Drive belts
     
    Engine ground cable
     
    Electrical connector from the crank angle sensor
     
    Engine electrical harness connectors
     



    Fuel feed and fuel return hoses
     
    Upper and lower radiator hoses
     
    Heater inlet and outlet hoses
     
    Engine vacuum hoses
     
    Carbon canister hoses
     
    Any interfering engine accessory: power steering pump, air conditioning compressor, and the alternator
     

  12.  
  13. Remove the carbon canister.
  14.  
  15. Remove the auxiliary fan, washer tank, and the radiator (with the fan assembly).
  16.  
  17. If equipped with a manual transaxle, remove the clutch release cylinder from the clutch housing.
  18.  
  19. If equipped with a manual transaxle, disconnect the shift control rod and disconnect the shift support rod.
  20.  
  21. If equipped with a automatic transaxle, disconnect the control cable from the transaxle.
  22.  
  23. Install engine slingers to the block and connect a suitable lifting device to the slingers. Do not tension the lifting device at this point.
  24.  
  25. Disconnect the exhaust pipe at both the manifold connections and remove the front exhaust pipe from the vehicle.
  26.  
  27. If equipped with a manual transaxle, drain the transaxle gear oil.
  28.  
  29. Support the engine and transaxle assembly with proper jack.
  30.  
  31. Disconnect the right and left side halfshafts from their side flanges and remove the bolt holding the radius link support.
  32.  
  33. Lower the shifter and selector rods and remove the bolts from the motor mount brackets. Remove the nuts holding the front and rear motor mounts to the frame.
  34.  
  35. Remove the center crossmember assembly from the vehicle.
  36.  
  37. Lower the engine/transaxle assembly down and onto an engine stand.
  38.  

To install:

  1. Raise the engine/transaxle assembly into the vehicle. When raising the engine onto the mounts, make sure to keep it as level as possible.
  2.  
  3. Check the clearance between the frame and clutch housing and make sure the engine mount bolts are seated in the groove of the mounting bracket.
  4.  
  5. Remove the transaxle and engine jack assembly.
  6.  
  7. Install the center crossmember and secure the engine mounting bolts.
  8.  
  9. If removed, raise the shifter and selector rods to their normal operating positions and secure them with the mounting bolts.
  10.  
  11. Install the halfshafts.
  12.  
  13. Connect the exhaust pipe assembly.
  14.  
  15. Disconnect and remove the engine slingers.
  16.  
  17. If equipped with a automatic transaxle, connect the control cable to the transaxle.
  18.  
  19. If equipped with a manual transaxle, install the clutch release cylinder to the clutch housing.
  20.  
  21. Install the auxiliary fan, washer tank, and the radiator (with the fan assembly).
  22.  
  23. Install the carbon canister.
  24.  
  25. Connect and/or install the following:

    Any interfering engine accessory: power steering pump, air conditioning compressor, and the alternator
     
    Carbon canister hoses
     
    Engine vacuum hoses
     
    Heater inlet and outlet hoses
     
    Upper and lower radiator hoses
     
    Fuel feed and fuel return hoses
     
    Engine electrical harness connectors
     
    Electrical connector from the crank angle sensor
     
    Engine ground cable
     
    Drive belts
     

  26.  
  27. Connect the throttle linkage, then install the air cleaner, the air flow meter, and the air intake duct.
  28.  
  29. Fill the transaxle, the engine, and the cooling system to the proper levels with the appropriate fluids.
  30.  
  31. Install the hood and connect the negative battery cable.
  32.  
  33. Make all the necessary engine adjustments. Charge the air conditioning system, if discharged. Road test the vehicle for proper operation.
  34.  

 
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