Engine Removal/Installation Make sure jacks and safety stands are placed properly and hoist brackets are attached to correct positions on the engine. (See Section 1). Apply parking brake and block rear wheels, so car will not roll off stands and fall on you while working under it. CAUTION: Use fender covers to avoid damaging painted surfaces. 1. Disconnect the battery negative terminal first then the positive terminal. 2. Unbolt the hood brackets and remove the hood. Disconnect the washer fluid tube. 3. Drain the engine oil. Reinstall the drain plug with a new washer. 4. Drain the coolant from the radiator into a clean pan so it may be re-used. Remove the radiator cap to speed draining. Use care when removing radiator cap to avoid scalding by hot coolant or steam. 5. Drain transmission oil/fluid.use a 3/8" drive socket wrench to remove the drain plug. Reinstall the drain plug with a new washer. 6. Remove the air flow tube and air intake pipe. 7. Remove the battery base. CAUTION: Use care when storing the hood to avoid damaging the paint. CLUTCH CABLE AIR FLOW TUBE SPEEDOMETER CABLE THROTTLE CABLE BATTERY BASE AIR INTAKE PIPE ENGINE GROUND CABLE NOTE: Take care not to bend the cable when removing it. Always replace a kinked cable with a new one.
Disconnect the connectors SERVICE BOLT 12 N m (1.2 kg-m, 9 Ib-ft) BANJO BOLT 22 N m (2.2 kg-m, 16 Ib-ft) 8. Relieve fuel pressure by slowly loosening the service bolt on the fuel filter about one turn. (Section 11). Do not smoke while working on fuel system. Keep open flame away from work area. Drain fuel only into an approved container. HOSES SEALING WASHERS FUEL HOSE CAUTION: Before disconnecting any fuel line, the fuel pressure should be relieved as described above. Place a shop towel over the fuel filter to prevent pressurized fuel from spraying over the engine. CHARCOAL CANISTER FUEL FILTER UNDER-HOOD RELAY BOX BATTERY WIRES ENGINE COMPARTMENT HARNESS CONNECTORS TRANSMISSION GROUND CABLE O-RING DISTRIBUTOR CAP 9. Disconnect the engine compartment harness connectors, battery wires and transmission ground cable. 10. Disconnect the engine wire connectors and spark plug wires. 11. Remove the cap and bolts, then remove the distributor from the cylinder head. 8 X 1.25 mm 24 N m (2.4 kg-m, 17 Ib-ft) (cont'd)
Engine Removal/Installation (cont'd) CABLE END THROTTLE CABLE 12. Remove the throttle cable by loosening the lock nut and the throttle cable adjust nut, then slip the cable end out of the throttle bracket and accelerator linkage. NOTE: Take care not to bend the cable when removing it. Always replace a kinked cable with a new one. ADJUST NUT BRAKE BOOSTER VACUUM HOSE LOCK NUT ENGINE GROUND CABLE 6 mm BOLT 12 N m (1.2 kg-m, 9 Ib-ft) SUB-ENGINE HARNESS CONNECTOR HARNESS CLAMP
14. Disconnect the radiator hoses and heater hoses. 15. Disconnect the transmission fluid cooler hoses. 16. Remove the speedometer cable. 17. On Cars with A/C: Loosen the belt adjust bolt and idle pulley nut. Remove the compressor mount bolts, then lift the compressor out of the bracket with hoses attached, and wire it up to the front beam.
Engine Removal/Installtion (cont'd) (On Autmatic Cars:) 19. Remove the EX pipe A, EX pipe bracket, torque converter cover and cable holder. 20. Remove the shift control cable by removing the cotter pin, control pin and control lever roller from the control lever. NOTE: Take care not to bend the cable when removing it. Do not use pliers to remove the cable from the linkage. Always replace a kinked cable with a new one. On reassembly, check the cable adjustment (Section 16). 21. Remove the shift lever torque rod, shift rod and clutch cable. NOTE: On reassembly, slide the retainer back into place after driving in the spring pin. 22. Remove the right and left driveshafts. WHEELWELL SPLASH SHIELD CLUTCH CABLE ADJUST NUT (M/T only) SHIFT LEVER TORQUE ROD SHIFT ROD 39 N m (3.9 kg-m, 28 Ib-ft) 8 x 1.25 mm 22 N m (2.2 kg-m, 16 Ib-ft) EX PIPE BRACKET 6 x 1.0 mm 12 N m (1.2 kg-m, 9 Ib-ft) COTTER PIN TORQUE CONVERTER COVER CONTROL PIN SPRING PIN PIN RETAINER CONTROL LEVER CABLE HOLDER SHIFT CONTROL CABLE CONTROL ROLLER SHIFT ROD SHIFT LEVER TORQUE ROD 8 mm PIN PUNCH 8 x 1.25 mm 22 N m (2.2 kg-m, 16 Ib-ft) DRIVESHAFTS DAMPER FORK BOLT SELF-LOCKING NUT 65 N m (6.5 kg-m, 47 Ib-ft) GASKET GASKET BALL JOINT NUT COTTER PIN EX PIPE A ENGINE SPLASH SHIELD SELF-LOCKING NUT NOTE: Coat all precision finished surfaces with clean engine oil or grease. Tie plastic bags over the drivehaft ends.
23. Attach a chain hoist to the engine block hoist brackets and raise the hoist just enough to remove slack from the chain. 24. Remove the rear transmission mount bracket. 25. Remove the bolts from the front transmission mount. 26. Remove the bolts from the engine side mount. 27. Remove the bolts from the side transmission mount. REAR TRANSMISSION MOUNT BRACKET
Engine Removal/Installation (cont'd) 31. Install the engine in the reverse order of removal. After the engine is in place: Torque engine mount bolts in sequence shown. CAUTION: Failure to tighten the bolts in the proper sequence can cause excessive noise and vibration, and reduce bushing life: check that the bushings are not twisted or offset. Check that the spring clip on the end of each driveshaft clicks into place. CAUTION: Use new spring clips on installation. Bleed air from the cooling system at the bleed bolt with the heater valve open. Adjust the throttle cable. Adjust the alternator belt tension. Check the clutch pedal free play. Check that the transmission shifts into gear smoothly. Reinstall the A/C compressor and A/C wiring. Clean battery posts and cable terminals with sandpaper, assemble, then apply grease to prevent corrosion. Check the ignition tinning. (See Section 23). Charge the system and test performance. (See Section 21). Inspection for fuel leakage. After assembing fuel line parts, turn on the ignition switch (do not operate the starter) so that the fuel pump is operated for approximately two seconds and the fuel is pressurized. Repeat this operation two or three times and check whether any fuel leakage has occurred at any point in the fuel line. ENGINE MOUNT TORQUE SEQUENCE NOTE: Check the mount and bracket for damage. SIDE TRANSMISSON MOUNT Speedometer cable Installation: Align tab on cable end with slot in holder (page5-5). Install clip so bent leg is on groove side. After installing, pull speedometer cable to make sure it is secure. REAR TRANSMISSION MOUNT BRACKET 55N m(5.5kg-m, 40lb-ft) SPEEDOMETER CABLE SPECIAL BOLT 12x1.25 mm 60 N m (6.0 kg-m, 43 Ib-ft) ENGINE SIDE MOUNT FRONT TRANSMISSION MOUNT SPECIAL BOLT 60 N m (6.0 kg-m, 43 Ib-ft) 55N m(5.5kg-m, 40lb-ft)
Additional Torque Specifications: NOTE: For manifold replacement. (See Section 9) SIDE TRANSMISSION MOUNT AND BRACKET M/T: 39 N m (3.9 kg-m, 28 Ib-ft) REAR TRANSMISSION MOUNT AND BRACKET M/T: A/T: 60 N m (6.0 kg-m, 43 Ib-ft) 58 N m (5.8 kg-m, 42 Ib-ft) A/T: 55 N m (5.5 kg-m, 40 Ib-ft) INTAKE MANIFOLD BRACKET 39 N m (3.9 kg-m, 28 Ib-ft) 22 N m (2.2 kg-m, 16 Ib-ft) BOLT 60 N m (6.0 kg-m, 43 Ib-ft) FRONT TRANSMISSION MOUNT 55 N m (5.5 kg-m, 40 Ib-ft) BOLT 60 N m (6.0 kg-m, 43 Ib-ft) 45 N m (4.5 kg-m, 33 Ib-ft) ALTERNATOR BRACKET POWER STEERING PUMP BRACKET 10 X 1.25 mm 45 N m (4.5 kg-m, 33 Ib-ft) ENGINE SIDE MOUNT BRACKET ENGINE SIDE MOUNT 10X1.25 mm 45 N m (4.5 kg-m, 33 Ib-ft) COMPRESSOR BRACKET 75 N m (7.5 kg-m. 54 Ib-ft)