Nissan Sentra/Pulsar/NX 1982-1996 Repair Guide

Engine

Print

REMOVAL & INSTALLATION



1982-87 E15 and E16S Engines

See Figures 1, 2, 3, 4, 5 and 6



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of outer components on the exhaust manifold side-E15 and E16 engine



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of outer components on the intake manifold side-E15 and E16 engine



Click image to see an enlarged view

Fig. Fig. 3: Exploded view of top end inner components-E-Series engine



Click image to see an enlarged view

Fig. Fig. 4: Exploded view of bottom end inner components-E-Series engine



Click image to see an enlarged view

Fig. Fig. 5: Exploded view of outer components on the exhaust manifold side-E15ET engine



Click image to see an enlarged view

Fig. Fig. 6: Exploded view of outer components on the intake manifold side-E15ET engine

The following procedures are for the 1987 and earlier models equipped with 1.5L and 1.6L engines that are not fuel injected. For EFI equipped models, follow the procedures later in this section.

The engine and transaxle must be removed as a single unit. The engine and transaxle is removed from the top of the vehicle. You must situate the vehicle on as flat and solid a surface as possible. Place chocks or equivalent at front and rear of rear wheels to keep the vehicle from rolling.

  1. Mark the location of the hinges on the hood. Remove the hood by holding at both sides and unscrewing bolts.
  2.  
  3. Disconnect the battery cables and remove the battery.
  4.  
  5. Drain the coolant from the radiator, then remove the radiator and the heater hoses.
  6.  


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

  1. Remove the air cleaner-to-rocker cover hose and the air cleaner cover, then place a clean rag in the carburetor or throttle body opening to keep out the dirt or any foreign object.
  2.  

Disconnect and label all the necessary vacuum hoses and electrical connectors, for reinstallation purposes. 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.

  1. If equipped, disconnect the air pump cleaner and remove the carbon canister.
  2.  
  3. Remove the auxiliary fan, the washer tank and the radiator grille. Remove the radiator together with the fan motor assembly as a unit.
  4.  
  5. Remove the clutch control wire or cable from the transaxle. Remove the right and the left buffer rods but do not alter the length of these rods. Disconnect the speedometer cable from the transaxle and plug the hole with a clean rag.
  6.  
  7. If equipped with air conditioning, loosen the idler pulley nut and the adjusting bolt, then remove the compressor belt. Remove the compressor to one side and suspend on a wire. Do not disconnect the A/C hoses if at all possible. Remove the condenser and the receiver drier and place them on the right fender.
  8.  

If equipped with AC, DO NOT ATTEMPT TO UNFASTEN ANY OF THE REFRIGERANT HOSES. See Routine Maintenance for additional warnings. If equipped with power steering, loosen the idler pulley nut and adjusting bolt, then remove the drive belt and the power steering pulley.

  1. If equipped with a manual transaxle, disconnect the transaxle shifting rods by removing the securing bolts. If equipped with an automatic transaxle, disconnect the mounting bracket and the control wire from the transaxle.
  2.  
  3. Attach the engine sling, tool 1000501M00 and 1000623M00 or equivalent at each end of the engine block. Connect a chain or cable to the engine slingers.
  4.  
  5. Unbolt the exhaust pipe from the exhaust manifold. There are 3 bolts which attach the pipe to the manifold and bolts which attach the pipe support to the engine.
  6.  

Remove the tie rod ends and the lower ball joints. Disconnect the right and left side drive shafts from their side flanges and remove the bolt holding the radius link support. When drawing out the halfshafts, it is necessary to loosen the strut head bolts also be careful not to damage the grease seals.

  1. Remove the axle shafts. You can refer to Drive Train for the axle shaft removal and installation procedures.
  2.  
  3. Remove the radius link support bolt, then lower the transaxle shift selector rods.
  4.  
  5. Unbolt the engine from the engine and the transaxle mounts.
  6.  
  7. Using an overhead lifting device, attach it to the engine lifting sling and slowly remove the engine and transaxle assembly from the vehicle.
  8.  

When removing the engine, be careful not to knock it against the adjacent parts.

  1. Separate the engine from the transaxle if necessary.
  2.  

To install:
  1. Attach the transaxle to the engine and torque the bolts to 35 ft. lbs. (48 Nm).
  2.  
  3. Install all the necessary parts on the engine before lowering it into the vehicle, such as, spark plugs, water pump etc.
  4.  
  5. Lower the engine and transaxle as an assembly into the car and onto the frame, make sure to keep it as level as possible.
  6.  
  7. Check the clearance between the frame and clutch housing and make sure that the engine mount bolts are seated in the groove of the mounting bracket.
  8.  
  9. Install the motor mounts, remove the engine sling and install the buffer rods, tighten the engine mount bolts first, then apply a load to the mounting insulators before tightening the buffer rod and sub-mounting bolts.
  10.  
  11. If the buffer rod length has not been altered, they should still be correct. Shims are placed under the engine mounts, be sure to replace the exact ones in the correct places.
  12.  
  13. Install the transaxle shift selector rods or cable and attaching parts.
  14.  
  15. Install the axle shafts and the attaching parts.
  16.  
  17. Install the exhaust pipe to the manifold, it is a good idea to replace the gasket for the exhaust pipe at this time.
  18.  
  19. Install slave cylinder, clutch cable if so equipped and speedometer cable.
  20.  
  21. Install the condenser, receiver drier, air conditioning compressor, power steering pump and all drive belts.
  22.  
  23. Install the radiator with fan motor attached as assembly, radiator grille, washer tank and the auxiliary fan.
  24.  
  25. Install air pump cleaner, if so equipped and the carbon canister.
  26.  
  27. Install all other attaching parts such as brackets etc. and the air cleaner that were removed and connect all the vacuum hoses and the electrical connectors.
  28.  
  29. Connect the radiator and heater hoses and refill the system with the correct amount of antifreeze.
  30.  
  31. Install the battery and reconnect the battery cables.
  32.  
  33. Install the hood in the same location as you removed it from.
  34.  
  35. Fill and check all fluids, start engine, let it warm up and check for leaks.
  36.  
  37. Road test vehicle after you are sure there are no leaks.
  38.  

1983-87 1.7L Diesel Engine

See Figures 7 and 8



Click image to see an enlarged view

Fig. Fig. 7: Exploded view of outer components-1.7L diesel engine



Click image to see an enlarged view

Fig. Fig. 8: Exploded view of internal components-1.7L diesel engine

The engine and transaxle must be removed as a unit. Since the Sentra is a front wheel drive car, this is a fairly involved procedure. It is very important to label and mark all cables, hoses and vacuum lines during this procedure. Masking tape works well here. Marking both the disconnected cable, hose, etc., and where it was attached will help to avoid the "where did that go-'' later.


CAUTION
Be sure the car is on a flat, solid surface with the wheels chocked before beginning. Do not remove the engine until the exhaust system has cooled off completely; you will avoid burns and fuel line fires this way. Also, when unbolting the air conditioner compressor and idler pulley mount, DO NOT disconnect any air conditioning fittings or hoses.

  1. Scribe or draw a line around the hood mounting brackets on the underside of the hood, to facilitate installation later. Remove the hood.
  2.  
  3. Remove battery and battery support bracket.
  4.  
  5. Remove air cleaner and related hoses. Plug the air horn of the intake manifold with a clean rag to keep dirt out.
  6.  
  7. Drain engine coolant and remove radiator with the radiator cooling fan.
  8.  


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

  1. Remove the power steering pump, if equipped.
  2.  
  3. Do not disconnect the A/C hoses unless absolutely necessary. Unbolt the air conditioner compressor and idler pulley bracket from the cylinder block. Remove the compressor drive belt and hold the compressor unit upright, attached to the car with a wire or rope.
  4.  
  5. Disconnect the exhaust header pipe from the exhaust manifold.
  6.  
  7. Disconnect the manual transaxle control rod link support rod from the transaxle.
  8.  
  9. Disconnect the automatic transaxle control linkage from the transaxle.
  10.  
  11. Remove the lower ball joint. Do not reuse the nuts once they have been removed. Replace them with new nuts.
  12.  
  13. Drain the transaxle gear oil or fluid.
  14.  
  15. Disconnect the right and left halfshafts from the transaxle.
  16.  

When drawing out the halfshafts, it is necessary to loosen the strut head bolts so the struts can be rocked outward. Be careful not to damage the grease seal on the transaxle side.

  1. Disconnect the clutch cable.
  2.  
  3. Remove the speedometer cable with the pinion from the transaxle. Plug the hole from which the pinion gear was removed with a clean rag to keep out dirt.
  4.  
  5. Disconnect the accelerator cable.
  6.  
  7. Disconnect any vacuum and air hoses between the engine and vehicle body. Disconnect all cables, wires and harness connectors.
  8.  
  9. Disconnect the fuel hoses from the fuel filter.
  10.  
  11. Attach a suitable sling to the lifting eyelets on the engine.
  12.  
  13. Unbolt the engine mounts, and lift the engine up and away from the car. The transaxle can now be separated from the engine.
  14.  

To install:
  1. Install the engine with transaxle attached. When installing, make sure that the brake lines, brake master cylinder, etc., do not interfere with the engine and transaxle. Also make sure that the air conditioning compressor and power steering pump (if equipped) are securely out of the way when lowering the engine. Carefully work the engine/transaxle assembly into position. Then, install all mounting through bolts. Tighten the engine mount bolts, making sure there is some clearance in the rubber insulator. Remove the lifting sling and crane.
  2.  
  3. Connect the fuel hoses to the fuel filter. Connect all cables, wires, and harness connectors. Connect the vacuum and air hoses that run from the body to the engine assembly.
  4.  
  5. Connect and adjust the accelerator cable.
  6.  
  7. Remove the rag from the transaxle and install the speedometer drive pinion gear. Reconnect the speedometer cable.
  8.  
  9. Reconnect the clutch cable and adjust it as described in Drive Train .
  10.  
  11. Make sure the splined ends of the halfshafts are clean and then reinsert them into the transaxle. When they are securely locked in place, retorque the strut nuts where the tops of the struts are fastened to the body. Refer to Drive Train for additional details.
  12.  
  13. Install new transmission fluid of the specified type and of the amount specified in General Information & Maintenance .
  14.  
  15. Install both ball joints with new nuts and torque them as described in Brakes .
  16.  
  17. Connect the automatic transaxle control linkage to the transaxle. If the car has a manual transaxle, connect the control rod link support rod to the transaxle.
  18.  
  19. Connect the header pipe to the exhaust manifold.
  20.  
  21. Bolt the air conditioner compressor and idler pulley bracket to the cylinder block. Install the compressor drive belt.
  22.  
  23. Install the power steering pump, if the car has power steering. Refill the pump with approved fluid.
  24.  
  25. Install the radiator and cooling fan, and reconnect the fan electrical connector. Refill the cooling system with 50/50 ethylene glycol/water mix.
  26.  
  27. Remove the rag installed into the air horn or throttle body and install the air cleaner and related hoses.
  28.  
  29. Install the battery support bracket and the battery. When you are sure that all electrical connections are safely reconnected, reconnect the battery cables.
  30.  
  31. Install the hood with bolts loose. Align it with the marks made earlier and then torque the bolts to 15 ft. lbs. (20 Nm).
  32.  
  33. Bleed the fuel system as outlined in Fuel System .
  34.  
  35. Start the engine, check for leaks, bleed the cooling system, and recheck and if necessary refill all fluid reservoirs.
  36.  

1987-90 Fuel Injected Engines

See Figures 9, 10, 11, 12, 13, 14, 15, 16, 17 and 18



Click image to see an enlarged view

Fig. Fig. 9: Exploded view of outer components-CA16DE and CA18DE engines



Click image to see an enlarged view

Fig. Fig. 10: Exploded view of internal components-CA16DE and CA18DE engines



Click image to see an enlarged view

Fig. Fig. 11: Exploded view of outer components intake side-GA16i engine



Click image to see an enlarged view

Fig. Fig. 12: Exploded view of outer components exhaust side-GA16i engine



Click image to see an enlarged view

Fig. Fig. 13: Engine mounting-4WD Sentra



Click image to see an enlarged view

Fig. Fig. 14: Do not loosen this power valve adjusting screw on the CA16DE or CA18DE engine. This screw is adjusted at the factory



Click image to see an enlarged view

Fig. Fig. 15: Typical transaxle linkage attaching points



Click image to see an enlarged view

Fig. Fig. 16: Typical rear engine mount



Click image to see an enlarged view

Fig. Fig. 17: Typical left side engine mount



Click image to see an enlarged view

Fig. Fig. 18: Prying back on the halfshaft to remove it from the transaxle. Use care not to damage the seal

This procedure is for 1987-90 CA16DE, CA18DE, E16i and GA16i fuel injected models. Carbureted and diesel engine procedures for 1987 models can be found earlier in this section.

The GA16i engine cannot be removed separately from the transaxle. Even on the other models, it is recommended that the engine and transaxle be removed as a unit, then separated after removal. If equipped with 4WD, remove the engine, transaxle and transfer case together.

  1. Mark the hood hinge relationship and remove the hood.
  2.  
  3. Release the fuel system pressure, disconnect the negative (-) battery cable and raise and support the vehicle safely.
  4.  
  5. Drain the cooling system and the engine oil.
  6.  


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

  1. Remove the air cleaner and disconnect the throttle cable.
  2.  
  3. Disconnect or remove the following:

    Drive belts
     
    Ignition wire from the coil to the distributor
     
    Ignition coil ground wire and the engine ground cable
     
    Block connector from the distributor
     
    Fusible links
     
    Engine harness connectors
     
    Fuel and fuel return hoses
     
    Upper and lower radiator hoses
     
    Heater inlet and outlet hoses
     
    Engine vacuum hoses
     
    Carbon canister hoses and the air pump air cleaner hose
     
    Any interfering engine accessory: power steering pump, air conditioning compressor or alternator
     
    Driveshaft from transfer case.
     

  4.  

Make sure to matchmark the driveshaft flanges.

  1. Remove the air pump air cleaner.
  2.  
  3. Remove the carbon canister.
  4.  
  5. Remove the auxiliary fan, washer tank, grille and radiator (with fan assembly).
  6.  
  7. Remove the clutch cylinder from the clutch housing for manual transaxles.
  8.  
  9. Remove both buffer rods without altering the length of the rods. Disconnect the speedometer cable.
  10.  
  11. Remove the spring pins from the transaxle gear selector rods.
  12.  
  13. Install engine slingers to the block and connect a suitable lifting device to the slingers. Do not tension the lifting device at this point.
  14.  
  15. Disconnect the exhaust pipe at both the manifold connection and the clamp holding the pipe to the engine.
  16.  
  17. Remove the lower ball joint.
  18.  
  19. Drain the transaxle gear oil.
  20.  
  21. Disconnect the right and left side halfshafts from their side flanges and remove the bolt holding the radius link support.
  22.  

When drawing out the halfshafts, it is necessary to loosen the strut head bolts.

  1. Lower the shifter and selector rods and remove the bolts from the engine mount brackets. Remove the nuts holding the front and rear engine mounts to the frame. Disconnect the clutch and accelerator wires and remove the speedometer cable with its pinion from the transaxle.
  2.  
  3. Lift the engine/transaxle assembly up and away from the vehicle.
  4.  

To install:
  1. Lower the engine transaxle assembly into the vehicle. When lowering the engine onto the frame, 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. After installing the engine mounts, adjust and install the buffer rods. On the 1988-92 Sentra 4WD: front should be 3.50-3.58 in. (89-91mm), and the rear, 3.90-3.98 in. (99-101mm).
  6.  
  7. Tighten the engine mount bolts first, then apply a load to the mounting insulators before tightening the buffer rod and sub-mounting bolts.
  8.  
  9. Connect the clutch and accelerator wires and remove the speedometer cable with its pinion from the transaxle.
  10.  
  11. Raise the shifter and selector rods to their normal operating positions.
  12.  
  13. Connect the halfshafts.
  14.  
  15. Connect the lower ball joint.
  16.  
  17. Connect the exhaust pipe to the manifold connection and the clamp holding the pipe to the engine.
  18.  
  19. Disconnect the lifting device and remove the engine slingers.
  20.  
  21. Insert the spring pins into the transaxle gear selector rods.
  22.  
  23. Connect the speedometer cable.
  24.  
  25. Mount the clutch cylinder onto the clutch housing.
  26.  
  27. Install the auxiliary fan, washer tank, grille and radiator (with fan assembly).
  28.  
  29. Install the carbon canister.
  30.  
  31. Install the air pump air cleaner.
  32.  
  33. Install or connect all hoses, belts, harnesses, connectors and components that were necessary to remove the engine.
  34.  
  35. Connect the throttle cable and install the air cleaner.
  36.  
  37. Fill the transaxle and cooling system to the proper levels.
  38.  
  39. Install the hood and connect the negative (-) battery cable.
  40.  
  41. Make all the necessary engine adjustments. Charge the air conditioning system. Road test the vehicle for proper operation.
  42.  

1991-94 1.6L and 1991-96 2.0L Engines

See Figures 19 - 22



Click image to see an enlarged view

Fig. Fig. 19: Exploded view of outer components on the intake side-GA16DE engine



Click image to see an enlarged view

Fig. Fig. 20: Exploded view of outer components on the exhaust side-GA16DE engine



Click image to see an enlarged view

Fig. Fig. 21: Exploded view of outer components-SR20DE engine



Click image to see an enlarged view

Fig. Fig. 22: Exploded view of outer components exhaust side-SR20DE engine

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

The 1.6L (GA16DE) engine cannot be removed separately from the transaxle. Remove the engine and the transaxle as a unit. If equipped with 4WD, remove the engine, transaxle and transfer case together.

  1. Mark the hood hinge relationship and remove the hood.
  2.  
  3. Release the fuel system pressure, disconnect the negative (-) battery cable and raise and support the vehicle safely.
  4.  
  5. Drain the cooling system and the engine oil.
  6.  


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

  1. Remove the air cleaner and disconnect the throttle cable.
  2.  
  3. Disconnect or remove the following:
    1. Drive belts.
    2.  
    3. Ignition wire from the coil to the distributor
    4.  
    5. Ignition coil ground wire and the engine ground cable
    6.  
    7. Block connector from the distributor
    8.  
    9. Fusible links
    10.  
    11. Engine harness connectors
    12.  
    13. Fuel and fuel return hoses
    14.  
    15. Upper and lower radiator hoses
    16.  
    17. Heater inlet and outlet hoses
    18.  
    19. Engine vacuum hoses
    20.  
    21. Carbon canister hoses and the air pump air cleaner hose
    22.  
    23. Any interfering engine accessories: power steering pump, air conditioning compressor or alternator
    24.  
    25. Driveshaft from transfer unit for 4WD vehicles.
    26.  

  4.  

Make sure to matchmark the driveshaft flanges.

  1. Remove the air pump air cleaner.
  2.  
  3. Remove the carbon canister.
  4.  
  5. Remove the auxiliary fan, washer tank, grille and radiator (with fan assembly).
  6.  
  7. Remove the clutch cylinder from the clutch housing for manual transaxles.
  8.  
  9. Remove both buffer rods without altering the length of the rods. Disconnect the speedometer cable.
  10.  
  11. Remove the spring pins from the transaxle gear selector rods.
  12.  
  13. Install engine slingers to the block and connect a suitable lifting device to the slingers. Do not tension the lifting device at this point.
  14.  
  15. Disconnect the exhaust pipe at both the manifold connection and the clamp holding the pipe to the engine.
  16.  
  17. Remove the lower ball joints.
  18.  
  19. Drain the transaxle gear oil.
  20.  
  21. Disconnect the right and left side halfshafts from their side flanges and remove the bolt holding the radius link support.
  22.  

When drawing out the halfshafts, it is necessary to loosen the strut head bolts.

  1. Lower the shifter and selector rods, and remove the bolts from the engine mount brackets. Remove the nuts holding the front and rear engine mounts to the frame.
  2.  
  3. Disconnect the clutch and accelerator wires and remove the speedometer cable with its pinion from the transaxle.
  4.  
  5. Lift the engine/transaxle assembly up and away from the vehicle.
  6.  

To install:
  1. Lower the engine/transaxle assembly into the vehicle. When lowering the engine onto the frame, 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. After installing the engine mounts, adjust and install the buffer rods. The front should be 3.50-3.58 in. (89-91mm), and the rear 3.90-3.98 in. (99-101mm).
  6.  
  7. Tighten the engine mount bolts first, then apply a load to the mounting insulators before tightening the buffer rod and sub-mounting bolts.
  8.  
  9. Connect the clutch and accelerator wires and install the speedometer cable with its pinion to the transaxle.
  10.  
  11. Raise the shifter and selector rods to their normal operating positions.
  12.  
  13. Connect the halfshafts.
  14.  
  15. Connect the lower ball joints and install new cotter pins.
  16.  
  17. Connect the exhaust pipe to the manifold connection and the clamp holding the pipe to the engine.
  18.  
  19. Disconnect the lifting device and remove the engine slingers.
  20.  
  21. Insert the spring pins into the transaxle gear selector rods.
  22.  
  23. Connect the speedometer cable.
  24.  
  25. Mount the clutch cylinder onto the clutch housing.
  26.  
  27. Install the auxiliary fan, washer tank, grille and radiator (with fan assembly).
  28.  
  29. Install the carbon canister.
  30.  
  31. Install the air pump air cleaner.
  32.  
  33. Install or connect all hoses, belts, harnesses, connectors and components that were necessary to remove the engine.
  34.  
  35. Connect the throttle cable and install the air cleaner.
  36.  
  37. Fill the transaxle and cooling system to the proper levels.
  38.  
  39. Install the hood and connect the negative (-) battery cable.
  40.  
  41. Make all the necessary engine adjustments. Charge the air conditioning system. Road test the vehicle for proper operation.
  42.  

1995-96 1.6L Engine

See Figures 19, 20, 21 and 22



Click image to see an enlarged view

Fig. Fig. 24: Height adjustment of the buffer rod-GA16DE engine

The engine and transaxle are removed as one unit from the underside of the vehicle.


CAUTION
Fuel injection systems remain under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative and positive battery cables.
  4.  
  5. Remove the battery and battery tray from the vehicle.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Remove both front wheels.
  10.  
  11. Remove the engine under covers and remove the engine side covers.
  12.  
  13. Drain the coolant from the radiator and the engine block.
  14.  


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

  1. Drain the engine oil.
  2.  
  3. Remove the air cleaner assembly and remove air duct.
  4.  
  5. Note the locations and remove the vacuum hoses.
  6.  
  7. Disconnect the heater hoses from the engine.
  8.  
  9. If equipped, disconnect the A/T cooler hoses from the transaxle.
  10.  
  11. Disconnect the fuel hoses from the engine.
  12.  
  13. Note the locations and disconnect the harness and wiring connections.
  14.  
  15. Disconnect the throttle cable and the cruise control cable.
  16.  
  17. If equipped with automatic transaxle, disconnect the control cable.
  18.  
  19. Remove the cooling fans, radiator, and the recovery tank.
  20.  
  21. Remove the front driveshafts from the vehicle.
  22.  
  23. Remove the front exhaust pipe.
  24.  
  25. Disconnect the control rod and support rod from the transaxle.
  26.  
  27. Remove the starter motor and intake manifold support brackets.
  28.  
  29. Remove the engine drive belts.
  30.  
  31. Remove the alternator and adjusting brackets.
  32.  
  33. Remove the power steering pump and A/C compressor. It is not necessary to disconnect the lines.
  34.  
  35. Remove the cylinder head front mounting bracket.
  36.  
  37. Position a transmission jack under the transaxle and support the engine with engine slinger.
  38.  
  39. Remove the center crossmember.
  40.  
  41. On some models it may be necessary to remove the front stabilizer bar.
  42.  
  43. Remove the engine mounting bolts from both sides of the engine.
  44.  
  45. Slowly lower the jacking devices and remove the engine and transaxle from the vehicle.
  46.  

To install:
  1. Install the engine and transaxle assembly.
  2.  
  3. Install the mounting bolts on both sides of the engine.
  4.  
  5. For vehicles with manual transaxles, adjust the height of the mounting bracket (buffer rod). The distance between the two through bolts should be 2.126-2.205 in. (54-56mm).
  6.  
  7. Install the center crossmember and remove the engine support jacks. Remove the engine slinger.
  8.  
  9. If removed, install the front stabilizer bar.
  10.  
  11. If removed, install the cylinder head front mounting bracket.
  12.  
  13. Install the power steering pump and A/C compressor.
  14.  
  15. Install the alternator assembly.
  16.  
  17. Install and adjust the engine drive belts.
  18.  
  19. Install the support brackets to the starter motor and the intake manifold.
  20.  
  21. Connect the control rod and support rod to the transaxle.
  22.  
  23. Tighten the control rod bolt to 10-13 ft. lbs. (14-18 Nm). Tighten the support rod bolt to 26-35 ft. lbs. (35-47 Nm).
  24.  
  25. Install the front exhaust pipe.
  26.  
  27. Install the front driveshafts.
  28.  
  29. Install the recovery tank, radiator, and the cooling fans.
  30.  
  31. If equipped with automatic transaxle, connect and adjust the control cable.
  32.  
  33. Connect the throttle cable and the cruise control cable. Adjust as necessary.
  34.  
  35. Connect the harness and wiring connections.
  36.  
  37. Using new clamps, connect the fuel hoses to the engine.
  38.  
  39. If removed, connect the A/T cooler hoses to the transaxle.
  40.  
  41. Using new clamps, connect the heater hoses to the engine.
  42.  
  43. Using noted locations, connect the vacuum hoses.
  44.  
  45. Install the air cleaner assembly and connect the air duct.
  46.  
  47. Refill the engine oil and cooling system.
  48.  
  49. Install the engine side covers and the engine under covers.
  50.  
  51. Install both front wheels.
  52.  
  53. Install the battery tray and install the battery.
  54.  
  55. Connect the positive and then the negative (-) battery cables.
  56.  
  57. Start the engine and check for leaks. Make all the necessary adjustments.
  58.  

 
label.common.footer.alt.autozoneLogo