Kia_Sephia_Rio_Spectra_Optima_1998-2006

Engine

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Battery cables
     
    Battery and tray
     

  6.  
  7. Drain and recycle the engine coolant.
  8.  
  9. Remove or disconnect the following:

    Data Link (DLC) from the Mass Air Flow (MAF) sensor bracket
     
    Intake Air Temperature (IAT) and Mass Air Flow (MAF) sensor connectors
     
    Air intake hose from the throttle body
     
    Ventilation hose and fresh air duct
     
    Accelerator and, if equipped, cruise control cables
     
    Air cleaner assembly
     
    Brake booster and purge control vacuum hoses from the intake manifold
     
    Upper and lower radiator hoses
     
    Fuel hose from the fuel injector rail
     
    Heater hoses
     
    Idle Air Control (IAC) and Throttle Position (TP) sensor connectors
     
    Fuel injector electrical connectors
     
    Starter and generator electrical connectors
     
    Engine ground strap
     
    Left and right splash shields
     
    Exhaust manifold heat shield and 3 power steering pump bracket bolts
     
    Air conditioning compressor mounting bolts and position it aside leaving the hoses attached
     
    Ground strap from the top of the transaxle
     
    No. 4 engine mount
     
    Input/turbine speed sensor connector, if equipped with an automatic transaxle
     
    Back-up light switch, if equipped with a manual transaxle
     
    Vehicle Speed Sensor (VSS)
     
    U-clip from the selector cable and the nut and washer from the transaxle linkage, if equipped with an automatic transaxle
     
    Linkage and extension bar, then the clutch release cylinder and hydraulic hose, if equipped with a manual transaxle
     
    Transaxle range switch and solenoid valve connectors, then the 2 transaxle oil cooler hoses, if equipped with an automatic transaxle
     
    Front wheels
     
    Oxygen (O 2 ) sensor electrical connectors
     
    Front exhaust pipe
     
    Halfshafts
     

  10.  
  11. Properly support the engine/transaxle assembly.
  12.  
  13. Remove or disconnect the following:

    2 No. 2 engine mount-to-mounting member mounting bolts
     
    1 bolt from the No. 3 engine mount
     
    3 No. 1 engine mounting bolts, then carefully lift the engine/transaxle assembly from the vehicle
     

  14.  

To install:

  1. Installation is the reverse of the removal procedure. Note the following important steps.
  2.  
  3. When possible, leave the engine mounting nuts/bolts loose (hand tight) until all mounts are aligned and bolted. This may help in aligning the engine/transaxle assembly in the vehicle.
  4.  
  5. Tighten the engine mount bolts/nuts as follows:

    No. 1 mounting bolts: 50-70 ft. lbs. (67-93 Nm)
     
    No. 3 mounting bolts: 63-86 ft. lbs. (85-116 Nm)
     
    No. 2 mounting nuts: 28-38 ft. lbs. (38-51 Nm)
     
    No. 4 mounting bolts: 47-66 ft. lbs. (64-89 Nm)
     
    No. 4 mounting nuts: 49-68 ft. lbs. (68-93 Nm)
     

  6.  
  7. Install new circlips on the inner CV-joint stub shafts, if equipped, intermediate shaft. Grease the shaft splines before installing the halfshaft/intermediate shaft into the transaxle.
  8.  
  9. Always install new gaskets and/or O-rings. Use new self-locking nuts, especially on the exhaust.
  10.  
  11. Fill the engine and the transaxle with the proper types and quantities of oil. Fill the cooling system.
  12.  
  13. Connect the negative battery cable, start the engine and check for leaks. Check all fluid levels.
  14.  

1.5L And 1.6L (VIN 5) Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain and recycle the engine coolant.
  6.  
  7. Disconnect the battery cables.
  8.  
  9. Remove the battery and tray.
  10.  
  11. Remove the fresh air intake duct.
  12.  
  13. Remove the upper and lower radiator hoses.
  14.  
  15. Disconnect the accelerator cable.
  16.  
  17. Disconnect the fuel hose from the fuel rail.
  18.  
  19. Remove the heater hose.
  20.  
  21. Disconnect the brake vacuum hose and purge control hose from the dynamic chamber.
  22.  
  23. Disconnect the injector connectors.
  24.  
  25. Disconnect the electrical connectors, tag before removing.
  26.  
  27. Remove the transaxle linkage, if equipped with an automatic transaxle.
  28.  
  29. Remove the manual transaxle linkage and extension bar, if equipped.
  30.  
  31. Remove the clutch release cylinder and pipe, if equipped.
  32.  
  33. Disconnect the transaxle range switch connector, solenoid valve connector and fluid cooler hose, if equipped with an automatic transaxle.
  34.  
  35. Disconnect the power steering pump hose.
  36.  
  37. Disconnect the B and S-terminal connectors from starter.
  38.  
  39. Disconnect the alternator B-terminal connector.
  40.  
  41. Remove the 4 A/C compressor mounting bolts, but do not disconnect the fluid line. Position the compressor aside.
  42.  
  43. Remove the front wheels.
  44.  
  45. Disconnect the front exhaust pipe from the manifold.
  46.  
  47. Remove the right and left tie rod ends from the steering knuckle.
  48.  
  49. Remove the bolt and nut, then separate the right and left lower control arm from the steering knuckle.
  50.  
  51. Remove the 2 bolts and nuts from the damper, then separate the damper from the knuckle.
  52.  
  53. Remove the halfshafts from the transaxle, by carefully prying them.
  54.  
  55. Support the engine with a suitable hoist.
  56.  
  57. Remove the 4 nuts and bolts from the engine mounting member.
  58.  
  59. Remove the 2 bolts from the No. 1 engine mounting bracket.
  60.  
  61. Remove the 4 bolts from the No. 2 engine mounting bracket.
  62.  
  63. Remove the 2 nuts from the No. 3 engine mounting rubber.
  64.  
  65. Remove the engine and transaxle assembly by lifting it out of the engine compartment as a unit.
  66.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the engine mount and brackets-1.5L and 1.6L (VIN 5) engine

  1. Installation is the reverse of the removal procedure. Note the following important steps.
  2.  
  3. When possible, leave the engine mounting nuts/bolts loose (hand tight) until all mounts are aligned and bolted. This may help in aligning the engine/transaxle assembly in the vehicle.
  4.  
  5. Tighten the engine mount bolts/nuts as follows:

    No. 3 engine mounting rubber (insulator) bolts: 49-68 ft. lbs. (68-93 Nm)
     
    No. 2 engine mounting nuts: 49-68 ft. lbs. (68-93 Nm)
     
    No. 2 engine mounting bolts: 28-38 ft. lbs. (38-51 Nm)
     
    Engine mounting member nuts: 28-38 ft. lbs. (39-52 Nm)
     
    Engine mounting member bolts: 47-66 ft. lbs. (65-91 Nm)
     

  6.  
  7. Install new circlips on the inner CV-joint stub shafts, if equipped, intermediate shaft. Grease the shaft splines before installing the halfshaft/intermediate shaft into the transaxle.
  8.  
  9. Always install new gaskets and/or O-rings. Use new self-locking nuts, especially on the exhaust.
  10.  
  11. Fill the engine and the transaxle with the proper types and quantities of oil. Fill the cooling system.
  12.  
  13. Connect the negative battery cable, start the engine and check for leaks. Check all fluid levels.
  14.  

1.6L (VIN 3) Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Drain the transaxle.
  10.  
  11. Recover the A/C refrigerant.
  12.  
  13. Remove or disconnect the following:

    Battery cables
     
    Battery
     
    Engine cover
     
    Engine splash guard
     
    Air intake assembly
     
    Battery tray
     
    Radiator hoses
     
    Transmission cooler hoses
     
    Heater hoses
     
    Fuel hose
     
    Throttle cable
     
    Throttle Position Sensor (TPS) connector
     

  14.  
  15. Disconnect the following wiring harnesses and clamps from the cylinder head and intake manifold:

    Rear O 2 sensor connector
     
    A/C compressor switch connector
     
    Knock sensor
     
    Fuel injectors
     
    Top wiring harnesses bracket
     
    Idle Speed Actuator (ISA) connector
     
    Front O 2 sensor connector
     
    Crankshaft Position Sensor (CPS) connector
     
    Oil Control Valve (OCV) connector
     
    Ignition coil connectors
     
    Camshaft Position Sensor (CMP) connector
     
    Ground cables
     

  16.  
  17. Remove the following wiring harnesses from vehicles equipped with automatic transmissions:

    Transaxle range switch connector
     
    Solenoid valve connector
     
    ATF oil temperature sensor
     
    Vehicle Speed Sensor (VSS) connector
     
    Band server switch connector
     
    Pulse generator connectors
     

  18.  
  19. Remove the following wiring harnesses from vehicles equipped with manual transmissions:

    VSS connector
     
    Neutral switch connector
     
    Back-up lamp switch
     

  20.  
  21. Remove or disconnect the following:

    Transmission control cable
     
    Purge Control Solenoid Valve (PCSV) hose
     
    Brake booster vacuum hose
     
    Power steering fluid hoses
     
    High and low A/C pressure hoses
     
    Engine mounting support bracket
     
    Transaxle mounting bracket
     
    Alternator connectors
     
    Front tires
     
    ABS wheel speed sensors
     
    Caliper assembly and securely hang the assembly from the vehicle
     
    Wheel knuckle mounting bolts
     
    Steering U-joint mounting bolts
     
    Front muffler
     

  22.  
  23. Using a suitable jack, secure the engine and transaxle assembly.
  24.  
  25. Remove the sub frame mounting bolts and nuts.
  26.  
  27. Remove the engine and transaxle assembly by lifting the vehicle.

    Click image to see an enlarged view

    Fig. Engine mounting support bracket-1.6L (VIN 3)



    Click image to see an enlarged view

    Fig. Transaxle mounting bracket-A/T-1.6L (VIN 3)



    Click image to see an enlarged view

    Fig. Transaxle mounting bracket-M/T-1.6L (VIN 3)



    Click image to see an enlarged view

    Fig. Sub frame mounting bolts and nuts-1.6L (VIN 3)

  28.  

To install:

  1. Installation is the reverse of removal.
  2.  
  3. Tighten the mounting bolts as follows:
    1. Sub frame mounting bolts and nuts: 69-87 ft. lbs. (93-118 Nm).
    2.  
    3. Transaxle mounting bracket: 51-69 ft. lbs. (69-93 Nm).
    4.  
    5. Engine mounting support bracket: Body side nut to 51-69 ft. lbs. (69-93 Nm). Engine side nuts to 36-47 ft. lbs. (49-64 Nm).
    6.  

  4.  
  5. Refill the engine with oil to the correct level.
  6.  
  7. Refill the cooling system to the correct level.
  8.  
  9. Refill the transaxle assembly to the correct level.
  10.  
  11. Adjust the throttle and shift cables as required.
  12.  
  13. Start the engine and check for leaks.
  14.  

1.8L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain and recycle the engine coolant.
  6.  
  7. Disconnect the battery cables.
  8.  
  9. Remove the battery and tray.
  10.  
  11. Remove the Data Link Connector (DLC) from the Mass Air Flow (MAF) sensor bracket.
  12.  
  13. Disconnect the Intake Air Temperature (IAT) and Mass Air Flow (MAF) sensor connectors.
  14.  
  15. Remove the air intake hose from the throttle body.
  16.  
  17. Remove the ventilation hose and fresh air duct.
  18.  
  19. Disconnect the accelerator and, if equipped, cruise control cables.
  20.  
  21. Remove the air cleaner assembly.
  22.  
  23. Disconnect the brake booster and purge control vacuum hoses from the intake manifold.
  24.  
  25. Remove the upper and lower radiator hoses.
  26.  
  27. Disconnect the fuel hose from the fuel injector rail.
  28.  
  29. Remove the heater hoses.
  30.  
  31. Disconnect the Idle Air Control (IAC) and Throttle Position (TP) sensor connectors.
  32.  
  33. Disconnect the fuel injector electrical connectors.
  34.  
  35. Disconnect the starter and alternator electrical connectors.
  36.  
  37. Disconnect the engine ground strap.
  38.  
  39. Remove the left and right splash shields.
  40.  
  41. Remove the exhaust manifold heat shield and 3 power steering pump bracket bolts.
  42.  
  43. Remove the air conditioning compressor mounting bolts and position it aside leaving the hoses attached.
  44.  
  45. Disconnect the ground strap from the top of the transaxle.
  46.  
  47. Remove the No. 4 engine mount.
  48.  
  49. Disconnect the input/turbine speed sensor connector, if equipped with an automatic transaxle.
  50.  
  51. Remove the back-up light switch, if equipped with a manual transaxle.
  52.  
  53. Remove the Vehicle Speed Sensor (VSS).
  54.  
  55. Remove the U-clip from the selector cable and the nut and washer from the transaxle linkage, if equipped with an automatic transaxle.
  56.  
  57. Remove the linkage and extension bar, then the clutch release cylinder and hydraulic hose, if equipped with a manual transaxle.
  58.  
  59. Disconnect the transaxle range switch and solenoid valve connectors, then the 2 transaxle oil cooler hoses, if equipped with an automatic transaxle.
  60.  
  61. Remove the front wheels.
  62.  
  63. Disconnect the Oxygen (O 2 ) sensor electrical connectors.
  64.  
  65. Disconnect the front exhaust pipe.
  66.  
  67. Remove the halfshafts.
  68.  
  69. Properly support the engine/transaxle assembly.
  70.  
  71. Remove the two No. 2 engine mount-to-mounting member bolts.
  72.  
  73. Remove the one bolt from the No. 3 engine mount.
  74.  
  75. Remove the three No. 1 engine mounting bolts, then carefully lift the engine/transaxle assembly from the vehicle.
  76.  

To install:

  1. Installation is the reverse of the removal procedure. Note the following important steps.
  2.  
  3. When possible, leave the engine mounting nuts/bolts loose (hand tight) until all mounts are aligned and bolted. This may help in aligning the engine/transaxle assembly in the vehicle.
  4.  
  5. Tighten the engine mount bolts/nuts as follows:

    No. 1 mounting bolts: 50-70 ft. lbs. (67-93 Nm)
     
    No. 3 mounting bolts: 63-86 ft. lbs. (85-116 Nm)
     
    No. 2 mounting nuts: 28-38 ft. lbs. (38-51 Nm)
     
    No. 4 mounting bolts: 47-66 ft. lbs. (64-89 Nm)
     
    No. 4 mounting nuts: 49-68 ft. lbs. (68-93 Nm)
     

  6.  
  7. Install new circlips on the inner CV-joint stub shafts, if equipped, intermediate shaft. Grease the shaft splines before installing the halfshaft/intermediate shaft into the transaxle.
  8.  
  9. Always install new gaskets and/or O-rings. Use new self-locking nuts, especially on the exhaust.
  10.  
  11. Fill the engine and the transaxle with the proper types and quantities of oil. Fill the cooling system.
  12.  
  13. Connect the negative battery cable, start the engine and check for leaks. Check all fluid levels.
  14.  

2.0L Engine
  1. Disconnect the battery terminals and remove the heat shield.
  2.  
  3. Remove the battery and battery tray.
  4.  
  5. Remove the engine cover.
  6.  
  7. Drain the engine coolant. Remove the radiator cap to speed draining.
  8.  
  9. Remove the intake air hose and air cleaner assembly.
  10.  
  11. Disconnect the AFS (Air Flow Sensor) connector.
  12.  
  13. Disconnect the breather hose from intake air hose.
  14.  
  15. Remove the intake air hose and air cleaner upper cover.
  16.  
  17. Remove the upper radiator hose and lower radiator hose.
  18.  
  19. Disconnect the ATF (Automatic Transaxle Fluid) cooler hose.
  20.  
  21. Remove the radiator.
  22.  
  23. Remove the heater hose.
  24.  
  25. Disconnect the accelerator cable.
  26.  
  27. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and the intake manifold.
  28.  
  29. Disconnect the OCV (Oil Control Valve) connector.
  30.  
  31. Disconnect the oil temperature sensor connector.
  32.  
  33. Disconnect the ECT (Engine Coolant Temperature) sensor connector.
  34.  
  35. Disconnect the ignition coil connector.
  36.  
  37. Disconnect the TPS (Throttle Position Sensor) connector.
  38.  
  39. Disconnect the ISA (Idle Speed Actuator) connector.
  40.  
  41. Disconnect the air conditioner compressor switch.
  42.  
  43. Disconnect the CMP (Camshaft Position Sensor) connector.
  44.  
  45. Disconnect the four fuel injector connectors.
  46.  
  47. Disconnect the knock sensor connector.
  48.  
  49. Disconnect the ground cables from the intake manifold and vehicle's body.
  50.  
  51. Disconnect the front heated oxygen sensor connector.
  52.  
  53. Disconnect the CKP (Crankshaft Position Sensor) connector.
  54.  
  55. Disconnect the oil pressure switch connector.
  56.  
  57. Disconnect the PCSV (Purge Control Solenoid Valve) connector.
  58.  
  59. Disconnect the transaxle wire harness connectors and control cable from transaxle (A/T).
  60.  
  61. Disconnect the transaxle range switch connector.
  62.  
  63. Disconnect the solenoid valve connector.
  64.  
  65. Disconnect the input shaft speed sensor connector.
  66.  
  67. Disconnect the output shaft speed sensor connector.
  68.  
  69. Disconnect the Vehicle Speed Sensor (VSS) connector.
  70.  
  71. Disconnect the transaxle ground cable.
  72.  
  73. Disconnect the control cable nut from transaxle range switch.
  74.  
  75. Disconnect the control cable.
  76.  
  77. Disconnect the fuel inlet hose of the delivery pipe side.
  78.  
  79. Disconnect the hose of the Purge Control Solenoid Valve (PCSV) side.
  80.  
  81. Remove the brake booster vacuum hose.
  82.  
  83. Remove the power steering pump drive belt.
  84.  
  85. Remove the power steering pump and use a wire to secure the pump to the vehicle so that it is out of the way.
  86.  
  87. Remove the front wheel (RH, LH).
  88.  
  89. Remove the bolts and RH side cover.
  90.  
  91. Remove the air conditioner compressor drive belt.
  92.  
  93. Remove the air conditioner compressor and fix the compressor to vehicle with a wire.
  94.  
  95. Disconnect the rear oxygen sensor connector and remove the clamp.
  96.  
  97. Disconnect the starter motor connector and "B" terminal connection.
  98.  
  99. Remove the mounting clip of the starter cable.
  100.  
  101. Remove the alternator connector and "B" terminal connection.
  102.  
  103. Remove the front muffler.
  104.  
  105. Remove the drive shaft.
  106.  
  107. Remove the front roll stopper.
  108.  
  109. Remove the rear roll stopper.
  110.  
  111. Install the engine hanger lift to the engine and transaxle assembly.
  112.  
  113. Remove the bolt, nuts and engine mounting support bracket.
  114.  
  115. Remove the transaxle mounting bracket.
  116.  
  117. Using engine hanger lift, remove the engine and transaxle assembly on vehicle.
  118.  

To install:

Click image to see an enlarged view

Fig. Front roll stopper-2.0L engine



Click image to see an enlarged view

Fig. Rear roll stopper-2.0L engine



Click image to see an enlarged view

Fig. Engine mount support bracket-2.0L engine



Click image to see an enlarged view

Fig. Transaxle mounting bracket bolts-2.0L engine



Click image to see an enlarged view

Fig. Transaxle mounting bracket bolt and nut-2.0L engine

  1. Installation is the reverse of the removal procedure. Note the following important steps.
  2.  
  3. When possible, leave the engine mounting nuts/bolts loose (hand tight) until all mounts are aligned and bolted. This may help in aligning the engine/transaxle assembly in the vehicle.
  4.  
  5. Tighten the engine mount bolts/nuts as follows:

    Front roll stopper bolt and nut: 36-47 ft. lbs. (49-63 Nm)
     
    Rear roll stopper bolt and nut: 36-47 ft. lbs. (49-63 Nm)
     
    Engine mount support bracket bolt (B) and nut (C): 36-47 ft. lbs. (49-63 Nm)
     
    Engine mount support bracket nut (D): 51-68 ft. lbs. (69-93 Nm)
     
    Transaxle mounting bracket bolts (A): 29-36 ft. lbs. (39-49 Nm)
     
    Transaxle mounting bracket nut (B): 65-79 ft. lbs. (88-108 Nm)
     

  6.  
  7. Always install new gaskets and/or O-rings. Use new self-locking nuts, especially on the exhaust.
  8.  
  9. Fill the engine and the transaxle with the proper types and quantities of oil. Fill the cooling system.
  10.  
  11. Adjust the shift cable.
  12.  
  13. Adjust the throttle cable.
  14.  
  15. Bleed the cooling system.
  16.  
  17. After, assemble the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.
  18.  
  19. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
  20.  
  21. Connect the negative battery cable, start the engine and check for leaks.
  22.  
  23. Bleed the cooling system.
  24.  
  25. Check all fluid levels.
  26.  

2.4L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain and recycle the engine coolant, transaxle fluid and engine oil.
  6.  
  7. Remove the battery.
  8.  
  9. Remove the air cleaner.
  10.  
  11. Disconnect the back-up lamp and engine harness connectors.
  12.  
  13. Disconnect the select control valve connector, if equipped with a manual transaxle.
  14.  
  15. Disconnect the alternator harness and oil pressure gauge wiring.
  16.  
  17. Disconnect the transaxle oil cooler hoses, if equipped with an automatic transaxle.
  18.  
  19. Remove the upper and lower radiator hoses from the engine.
  20.  
  21. Disconnect the engine ground.
  22.  
  23. Disconnect the brake booster vacuum hose.
  24.  
  25. Disconnect the main fuel line and return and vapor hoses from the engine side.
  26.  
  27. Disconnect the inlet and outlet heater hoses from the engine.
  28.  
  29. Disconnect the accelerator cable from the engine.
  30.  
  31. Disconnect the clutch cable, shift control rod and extension rod if equipped with a manual transaxle.
  32.  
  33. Disconnect the control cable from the transaxle, if equipped with an automatic transaxle.
  34.  
  35. Disconnect the Vehicle Speed Sensor (VSS) connector from the transaxle.
  36.  
  37. Disconnect the column shaft from the steering gear box.
  38.  
  39. Remove the engine and transaxle mounting insulators.
  40.  
  41. Remove the wheel.
  42.  
  43. Remove the caliper. Unbolt and support with a piece of wire. Do not disconnect the brake fluid line.
  44.  
  45. Remove the lower arm and fork and separate the upper arm and knuckle.
  46.  
  47. Disconnect the front exhaust pipe from the manifold. Use wire to hang the exhaust pipe from the bottom of the vehicle.
  48.  
  49. Place a suitable supporter under the sub-frame. Make sure all hoses, vacuum lines and connectors are detached from the engine.
  50.  
  51. Loosen the sub-frame bolts, then slowly lift the vehicle. The engine/transaxle, sub-frame, steering gear and halfshafts are removed as an assembly.
  52.  
  53. Remove the halfshafts, raise the engine/transaxle assembly with a hoist, and separate the engine and transaxle from the sub-frame.
  54.  
  55. To separate the engine/transaxle from the sub-frame, remove the engine mounting bracket and transaxle mounting bracket, then lift up the engine hoist.
  56.  

To install:

  1. To place the engine and transaxle assembly on the sub-frame, install the front roll stopper and rear roll stopper among the sub-frame and engine/transaxle assembly.
  2.  
  3. Installation is the reverse of the removal procedure, noting the following steps:
    1. Fill the engine and the transaxle with the proper types and quantities of oil.
    2.  
    3. Fill the cooling system.
    4.  
    5. Start the engine and check for leaks. Check all fluid levels.
    6.  

  4.  

2.7L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain and recycle the engine coolant and engine oil.
  6.  
  7. Remove the battery and engine cover.
  8.  
  9. Remove the air cleaner.
  10.  
  11. Disconnect the engine harness connectors.
  12.  
  13. Remove the alternator harness, oil pressure switch and oil pressure sender connectors.
  14.  
  15. Disconnect the transaxle oil cooler hoses.
  16.  
  17. Remove the upper and lower radiator hoses from the engine.
  18.  
  19. Remove the radiator.
  20.  
  21. Disconnect the spark plug wires.
  22.  
  23. Disconnect the engine ground.
  24.  
  25. Disconnect the brake booster vacuum hose.
  26.  
  27. Disconnect the main fuel line and return and vapor hoses from the engine side.
  28.  
  29. Remove the inlet and outlet heater hoses from the engine.
  30.  
  31. Disconnect the accelerator and cruise control cables from the engine.
  32.  
  33. Disconnect the control cable from the transaxle.
  34.  
  35. Remove the speedometer cable from the transaxle.
  36.  
  37. Remove the power steering pump hose.
  38.  
  39. Remove the oil pan shield.
  40.  
  41. Disconnect the front exhaust pipe from the manifold. Use a wire to support the exhaust pipe from the bottom of the vehicle.
  42.  
  43. Remove the lower control arm ball joint bolts and upper arm bolt from the steering knuckle.
  44.  
  45. Remove the halfshafts from the transaxle. Plug the openings in the transaxle case and discard the halfshaft circlips.
  46.  
  47. Attach a cable or chain to the engine and use a chain hoist to lift the engine enough to pull the cable tight.
  48.  
  49. Remove the front and rear roll stoppers.
  50.  
  51. Disconnect the connector from the starter motor harness.
  52.  
  53. Remove the engine mount bolts.
  54.  
  55. Remove the bolts and nuts that fasten the engine mount bracket to the body.
  56.  
  57. Slowly raise the engine and transaxle assembly and temporarily hold in the raised position. Make sure that all hoses, cables, vacuum lines and connectors are detached from the engine.
  58.  
  59. Remove the transaxle mounting bracket bolts.
  60.  
  61. Remove the left mount insulator bolt.
  62.  
  63. Remove the engine and transaxle assembly. While directing the transaxle side down, lift the engine and transaxle up and out of the vehicle.
  64.  

To install:

  1. Installation is the reverse of the removal procedure, noting the following steps:
    1. Fill the engine and the transaxle with the proper types and quantities of oil.
    2.  
    3. Fill the cooling system.
    4.  
    5. Start the engine and check for leaks. Check all fluid levels.
    6.  

  2.  

 
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