REMOVAL & INSTALLATION
The engine and transmission are removed together and then separated when out of the car. Always observe the following cautions:
- Mark the location of the hinges on the hood. Unbolt and remove the hood.
- Disconnect the battery cables. Remove the battery from the models with the L16 engine and Z20E models with air conditioning.
- Drain the coolant and automatic transmission fluid.
When draining the coolant, keep in mind that cats and dogs are attracted by 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.
- Remove the grille on the 510, 610, and 710 models. Remove the radiator and radiator shroud after disconnecting the automatic transmission coolant tubes.
- Remove the air cleaner.
- Remove the fan and pulley.
- water temperature gauge wire;
- oil pressure sending unit wire;
- ignition distributor primary wire;
- starter motor connections;
- fuel hose;
- alternator leads;
- heater hoses;
- throttle and choke connections;
- engine ground cable;
- thermal transmitter wire;
- wire to fuel cut-off solenoid;
- vacuum cut solenoid wire.
A good rule of thumb when disconnecting the rather complex engine wiring of today's cars is to put a piece of masking tape on the wire and on the connection you removed the wire from, then mark both pieces of tape 1, 2, 3, etc. When replacing wiring, simply match the pieces of tape.
- Disconnect the power brake booster hose from the engine.
- Remove the clutch operating cylinder and return spring.
- Disconnect the speedometer cable from the transmission. Disconnect the backup light switch and any other wiring or attachments to the transmission. On cars with the L18 models, remove the boot, withdraw the lock pin, and remove the lever from inside the car.
- Detach the exhaust pipe from the exhaust manifold. Remove the front section of the exhaust system. Be careful not to break the retaining bolts to manifold. If the bolts or studs break in the manifold remove the manifold and drill and tap the hole.
- Mark the relationship of the driveshaft flanges and remove the driveshaft.
- Place a jack under the transmission. Remove the rear crossmember.
- Attach a hoist to the lifting hooks on the engine (at either end of the cylinder head). Support the engine.
- Unbolt the front engine mounts. Tilt the engine by lowering the jack under the transmission and raising the hoist.
- With the engine/transmission assembly mounted safely on the engine hoist slowly lower the engine/transmission assembly into place.
- Support the transmission with a jack or equivalent until the crossmember is installed.
- Tighten the front engine mounts. It may be necessary to lower or raise the engine hoist to correctly position the engine assembly to line up with the mount holes. Remove the engine hoist.
- Install the crossmember then remove the jack or equivalent supporting the transmission.
- Install the driveshaft in the correct marked position.
- Reconnect the front exhaust system to the exhaust manifold. Be careful not to tighten retaining bolts to manifold to tight. If the bolts or studs break in the manifold remove the manifold and drill and tap the hole.
- Reconnect all wiring at the transmission and the speedometer cable.
- On cars with the L18 engine, install the lever, lock pin and shift boot.
- Install the clutch cylinder and return spring. Reconnect the power brake hose to the engine if so equipped.
- Install all wiring, brackets, vacuum hoses and water hoses to the engine. Make sure all connections are tight and in the correct location. It is always a good idea to replace all the old water hoses when installing the engine.
- Install the fan and fan pulley.
- Install the radiator shroud than the radiator reconnect the transmission lines if so equipped. Install the front grille if it was removed.
- Refill the radiator and all other fluid levels.
- Install the air cleaner, battery and reconnect the battery cables.
- Install the hood in the same location as you removed it from.
- Check all fluids, start the engine, let it warm up and check for leaks.
- Road test vehicle after you are sure there are no leaks.
On these models no standard engine removal and installation procedures are given by the manufacturer. However it is recommended the engine and transaxle be removed as a single unit. Always release the fuel pressure in the system before disconnecting the fuel lines. Situate the vehicle on as flat and solid a surface as possible. Place chocks or equivalent at front and rear of rear wheels to stop vehicle from rolling while working on the vehicle. To remove the engine and transaxle assembly the front halfshafts will have to be removed from the transaxle refer to in this guide.