|
|
levels to proper level. Removal (1.6L & 1.6L Turbo) 1. Relieve fuel pressure and discharge air conditioning system (if equipped). See FUEL PRESSURE RELEASE under REMOVAL & INSTALLATION. Disconnect and remove battery, battery tray and battery tray support bracket. 2. Release wiring harness retaining straps from battery support tray. Disconnect windshield washer supply hose between fluid reservoir and hood. Mark hinge locations and remove hood. 3. Disconnect intake air tube and wiring to ignition coil and vane airflow meter. Remove air cleaner/vane airflow meter assembly. Remove air cleaner assembly support brackets. Disconnect intercooler hoses from turbocharger (if equipped). 4. Drain engine coolant and remove radiator. Disconnect accelerator cable, and remove retaining bracket from cam cover. Position cable to one side. 5. Disconnect and plug fuel lines at fuel filter and pressure regulator. Disconnect power brake booster manifold vacuum hose from manifold. Disconnect heater hoses at heater core tubes. Label and remove vacuum hoses located at throttle body. 6. For instruction transaxle turbocharged vehicles, disconnect clutch cable and remove support bracket and cable from transmission. On non- turbo vehicles, disconnect clutch slave hydraulic line. For automatic transaxle, remove transaxle cooler lines. 7. Disconnect starter wiring at starter. Remove harness from locating strap on bracket. Disconnect alternator wiring. Disconnect wiring from engine coolant sensors located on rear of engine block. Remove ground connection at bracket on thermostat cover. Disconnect O2 8. Remove engine oil dipstick and retaining clip. Remove power steering pump from mounting bracket. Remove power steering pump mounting bracket. With hoses attached, position pump aside. Remove upper air conditioning compressor retaining bolts (if equipped). 9. Raise vehicle on hoist. Drain engine oil and cooling system. On vehicles with air conditioning, remove lower air conditioning compressor mounting bolts, and position compressor out of way. 10. Remove front wheels and tires. Remove front ball joints-to-steering knuckles retaining bolts. Remove splash guards. Drain transmission oil and remove half shafts from differential. Remove front exhaust pipe bracket located on lower side of engine. Disconnect front 11. Remove frame support bar-to-engine support bolt. Loosen right control arm bolt and, pivot support bar downward. Disengage rubber exhaust hangers located directly behind catalytic converter. Allow exhaust system to hang down 6 inches, and support system with 12. Attach chains onto lift eyes at ends of cylinder head, and support engine with hoist. Remove RH engine mount through bolt. Raise engine off mounts and slightly pivot engine/transaxle assembly. Disconnect oil pressure sensor and route starter/alternator wiring 13. Remove intake manifold support bracket. Remove gusset plate(s) (if equipped). Remove starter. Remove transaxle-to-engine retaining bolts. Identify bolts to ensure correct installation. Separate transaxle from engine. On instruction transaxle, remove pressure plate, clutch Installation (1.6L & 1.6L Turbo) 1. Install transaxle to engine in reverse order of removal. Attach hoist to engine/transaxle assembly and position assembly in vehicle. Before engine contacts mounts, route starter, alternator and oil pressure sensor wiring, and connect oil pressure sensor. Lower engine 2. Remove hoist. Raise vehicle and support with jackstands. Align rear engine mount to crossmember, and install retaining nuts to front and rear engine mounts. Tighten nuts to specification. See TORQUE SPECIFICATIONS table at end of article. 3. On instruction transaxles, connect shift coupling and stabilizer. Tighten to specification. On automatic transaxles, connect shift linkage and oil cooler lines. Tighten linkage retaining bolt, shift cable pivot and oil cooler hose clamps to specification. Connect front exhaust pipe 4. Install drive axles. Install ball joint retaining bolts and tighten to specification. Mount A/C Compressor to engine (if equipped). Tighten lower retaining bolts to specification. Install splash guards. Install tire and wheel assemblies. Tighten retaining nuts to specification. 5. Lower vehicle. Install upper A/C compressor retaining bolts (if equipped). Tighten bolts to specification. Tighten RH engine mount through bolt to specification. Connect alternator wiring. 6. Position power steering pump bracket on stud. Lower pump into engine compartment. Install power steering pump bracket retaining bolts and nut. Tighten to specification. Install power steering pump and belt. Tighten adjustment nut and pivot bolt to specification. 7. Install engine oil dipstick and retaining clip. Install ground strap and ground wire to cylinder head. Install clutch cable (if equipped). Connect clutch hydraulic line if equipped with instruction transaxle or naturally aspirated. Connect transmission electrical connectors. 8. Install intercooler hoses on turbocharged models. Install air cleaner assembly brackets. Install air cleaner assembly with airflow meter attached. Install intake air tube. Install coil and airflow meter connectors. Connect coolant crankcase and air bypass hoses. Install 9. Connect accelerator cable. Install retaining bracket. Install power brake booster hose. Remove speedometer cable from transaxle. Fill transaxle to specification. See CAPACITIES in SERVICE & ADJUSTMENT SPECIFICATIONS article. Install speedometer cable. 10. Install radiator/fan assembly. Tighten bracket retaining bolts to specification. Connect coolant hoses and fan electrical connector. Fill coolant to specification. 11. Install hood and connect washer hose. Install battery tray support, battery tray, battery and battery hold-down. Connect battery terminal. Evacuate and charge air conditioning system (if equipped). Road test vehicle and inspect for leaks. INTAKE MANIFOLD Removal (1.3L) CAUTION: DO NOT allow compressor to hang by hoses. Tie up compressor with mechanic's wire. |