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NissanSentra/Pulsar/NX19821996RepairGuide
REMOVAL&INSTALLATION

Engine

REMOVAL&INSTALLATION
198287E15andE16SEngines
SeeFigures1,2,3,4,5and6

Fig.Fig.1:ExplodedviewofoutercomponentsontheexhaustmanifoldsideE15andE16engine

UseCode:20COOL10 SeeDetails

Fig.Fig.2:ExplodedviewofoutercomponentsontheintakemanifoldsideE15andE16engine

Fig.Fig.3:ExplodedviewoftopendinnercomponentsESeriesengine

Fig.Fig.4:ExplodedviewofbottomendinnercomponentsESeriesengine

Fig.Fig.5:ExplodedviewofoutercomponentsontheexhaustmanifoldsideE15ETengine

Fig.Fig.6:ExplodedviewofoutercomponentsontheintakemanifoldsideE15ETengine
Thefollowingproceduresareforthe1987andearliermodelsequippedwith1.5Land1.6Lenginesthatarenotfuelinjected.ForEFIequippedmodels,followtheprocedures
laterinthissection.
Theengineandtransaxlemustberemovedasasingleunit.Theengineandtransaxleisremovedfromthetopofthevehicle.Youmustsituatethevehicleonasflatandsolida
surfaceaspossible.Placechocksorequivalentatfrontandrearofrearwheelstokeepthevehiclefromrolling.
1.Markthelocationofthehingesonthehood.Removethehoodbyholdingatbothsidesandunscrewingbolts.
2.Disconnectthebatterycablesandremovethebattery.
3.Drainthecoolantfromtheradiator,thenremovetheradiatorandtheheaterhoses.

CAUTION
Whendrainingenginecoolant,keepinmindthatcatsanddogsareattractedtoethyleneglycolantifreezeandcoulddrinkanythatisleftinanuncoveredcontainerorinpuddles
ontheground.Thiswillprovefatalinsufficientquantity.Alwaysdraincoolantintoasealablecontainer.Coolantshouldbereusedunlessitiscontaminatedorisseveralyears
old.

4.Removetheaircleanertorockercoverhoseandtheaircleanercover,thenplaceacleanraginthecarburetororthrottlebodyopeningtokeepoutthedirtoranyforeign
object.

Disconnectandlabelallthenecessaryvacuumhosesandelectricalconnectors,forreinstallationpurposes.Agoodruleofthumbwhendisconnectingtherathercomplexengine
wiringoftoday'scarsistoputapieceofmaskingtapeonthewireandontheconnectionyouremovedthewirefrom,thenmarkbothpiecesoftape1,2,3,etc.Whenreplacing
wiring,simplymatchthepiecesoftape.
5.Ifequipped,disconnecttheairpumpcleanerandremovethecarboncanister.
6.Removetheauxiliaryfan,thewashertankandtheradiatorgrille.Removetheradiatortogetherwiththefanmotorassemblyasaunit.
7.Removetheclutchcontrolwireorcablefromthetransaxle.Removetherightandtheleftbufferrodsbutdonotalterthelengthoftheserods.Disconnectthespeedometer
cablefromthetransaxleandplugtheholewithacleanrag.
8.Ifequippedwithairconditioning,loosentheidlerpulleynutandtheadjustingbolt,thenremovethecompressorbelt.Removethecompressortoonesideandsuspendon
awire.DonotdisconnecttheA/Chosesifatallpossible.Removethecondenserandthereceiverdrierandplacethemontherightfender.

IfequippedwithAC,DONOTATTEMPTTOUNFASTENANYOFTHEREFRIGERANTHOSES.SeeRoutineMaintenanceforadditionalwarnings.Ifequippedwithpower

steering,loosentheidlerpulleynutandadjustingbolt,thenremovethedrivebeltandthepowersteeringpulley.
9.Ifequippedwithamanualtransaxle,disconnectthetransaxleshiftingrodsbyremovingthesecuringbolts.Ifequippedwithanautomatictransaxle,disconnectthe
mountingbracketandthecontrolwirefromthetransaxle.
10.Attachtheenginesling,tool1000501M00and1000623M00orequivalentateachendoftheengineblock.Connectachainorcabletotheengineslingers.
11.Unbolttheexhaustpipefromtheexhaustmanifold.Thereare3boltswhichattachthepipetothemanifoldandboltswhichattachthepipesupporttotheengine.

Removethetierodendsandthelowerballjoints.Disconnecttherightandleftsidedriveshaftsfromtheirsideflangesandremovetheboltholdingtheradiuslinksupport.When
drawingoutthehalfshafts,itisnecessarytoloosenthestrutheadboltsalsobecarefulnottodamagethegreaseseals.
12.Removetheaxleshafts.YoucanrefertoDriveTrainfortheaxleshaftremovalandinstallationprocedures.
13.Removetheradiuslinksupportbolt,thenlowerthetransaxleshiftselectorrods.
14.Unbolttheenginefromtheengineandthetransaxlemounts.
15.Usinganoverheadliftingdevice,attachittotheengineliftingslingandslowlyremovetheengineandtransaxleassemblyfromthevehicle.

Whenremovingtheengine,becarefulnottoknockitagainsttheadjacentparts.
16.Separatetheenginefromthetransaxleifnecessary.

Toinstall:
17.Attachthetransaxletotheengineandtorquetheboltsto35ft.lbs.(48Nm).
18.Installallthenecessarypartsontheenginebeforeloweringitintothevehicle,suchas,sparkplugs,waterpumpetc.
19.Lowertheengineandtransaxleasanassemblyintothecarandontotheframe,makesuretokeepitaslevelaspossible.
20.Checktheclearancebetweentheframeandclutchhousingandmakesurethattheenginemountboltsareseatedinthegrooveofthemountingbracket.
21.Installthemotormounts,removetheengineslingandinstallthebufferrods,tightentheenginemountboltsfirst,thenapplyaloadtothemountinginsulatorsbefore
tighteningthebufferrodandsubmountingbolts.
22.Ifthebufferrodlengthhasnotbeenaltered,theyshouldstillbecorrect.Shimsareplacedundertheenginemounts,besuretoreplacetheexactonesinthecorrect
places.
23.Installthetransaxleshiftselectorrodsorcableandattachingparts.
24.Installtheaxleshaftsandtheattachingparts.
25.Installtheexhaustpipetothemanifold,itisagoodideatoreplacethegasketfortheexhaustpipeatthistime.
26.Installslavecylinder,clutchcableifsoequippedandspeedometercable.
27.Installthecondenser,receiverdrier,airconditioningcompressor,powersteeringpumpandalldrivebelts.
28.Installtheradiatorwithfanmotorattachedasassembly,radiatorgrille,washertankandtheauxiliaryfan.
29.Installairpumpcleaner,ifsoequippedandthecarboncanister.
30.Installallotherattachingpartssuchasbracketsetc.andtheaircleanerthatwereremovedandconnectallthevacuumhosesandtheelectricalconnectors.
31.Connecttheradiatorandheaterhosesandrefillthesystemwiththecorrectamountofantifreeze.
32.Installthebatteryandreconnectthebatterycables.
33.Installthehoodinthesamelocationasyouremoveditfrom.
34.Fillandcheckallfluids,startengine,letitwarmupandcheckforleaks.
35.Roadtestvehicleafteryouaresuretherearenoleaks.

1983871.7LDieselEngine
SeeFigures7and8

Fig.Fig.7:Explodedviewofoutercomponents1.7Ldieselengine

Fig.Fig.8:Explodedviewofinternalcomponents1.7Ldieselengine
Theengineandtransaxlemustberemovedasaunit.SincetheSentraisafrontwheeldrivecar,thisisafairlyinvolvedprocedure.Itisveryimportanttolabelandmarkall
cables,hosesandvacuumlinesduringthisprocedure.Maskingtapeworkswellhere.Markingboththedisconnectedcable,hose,etc.,andwhereitwasattachedwillhelpto
avoidthe"wheredidthatgo''later.

CAUTION
Besurethecarisonaflat,solidsurfacewiththewheelschockedbeforebeginning.Donotremovetheengineuntiltheexhaustsystemhascooledoffcompletelyyouwillavoid
burnsandfuellinefiresthisway.Also,whenunboltingtheairconditionercompressorandidlerpulleymount,DONOTdisconnectanyairconditioningfittingsorhoses.

1.Scribeordrawalinearoundthehoodmountingbracketsontheundersideofthehood,tofacilitateinstallationlater.Removethehood.
2.Removebatteryandbatterysupportbracket.
3.Removeaircleanerandrelatedhoses.Plugtheairhornoftheintakemanifoldwithacleanragtokeepdirtout.
4.Drainenginecoolantandremoveradiatorwiththeradiatorcoolingfan.

CAUTION
Whendrainingenginecoolant,keepinmindthatcatsanddogsareattractedtoethyleneglycolantifreezeandcoulddrinkanythatisleftinanuncoveredcontainerorinpuddles
ontheground.Thiswillprovefatalinsufficientquantity.Alwaysdraincoolantintoasealablecontainer.Coolantshouldbereusedunlessitiscontaminatedorisseveralyears
old.

5.Removethepowersteeringpump,ifequipped.
6.DonotdisconnecttheA/Chosesunlessabsolutelynecessary.Unbolttheairconditionercompressorandidlerpulleybracketfromthecylinderblock.Removethe
compressordrivebeltandholdthecompressorunitupright,attachedtothecarwithawireorrope.
7.Disconnecttheexhaustheaderpipefromtheexhaustmanifold.
8.Disconnectthemanualtransaxlecontrolrodlinksupportrodfromthetransaxle.
9.Disconnecttheautomatictransaxlecontrollinkagefromthetransaxle.
10.Removethelowerballjoint.Donotreusethenutsoncetheyhavebeenremoved.Replacethemwithnewnuts.
11.Drainthetransaxlegearoilorfluid.
12.Disconnecttherightandlefthalfshaftsfromthetransaxle.

Whendrawingoutthehalfshafts,itisnecessarytoloosenthestrutheadboltssothestrutscanberockedoutward.Becarefulnottodamagethegreasesealonthetransaxle
side.
13.Disconnecttheclutchcable.
14.Removethespeedometercablewiththepinionfromthetransaxle.Plugtheholefromwhichthepiniongearwasremovedwithacleanragtokeepoutdirt.
15.Disconnecttheacceleratorcable.
16.Disconnectanyvacuumandairhosesbetweentheengineandvehiclebody.Disconnectallcables,wiresandharnessconnectors.
17.Disconnectthefuelhosesfromthefuelfilter.
18.Attachasuitableslingtotheliftingeyeletsontheengine.
19.Unbolttheenginemounts,andlifttheengineupandawayfromthecar.Thetransaxlecannowbeseparatedfromtheengine.

Toinstall:
20.Installtheenginewithtransaxleattached.Wheninstalling,makesurethatthebrakelines,brakemastercylinder,etc.,donotinterferewiththeengineandtransaxle.Also
makesurethattheairconditioningcompressorandpowersteeringpump(ifequipped)aresecurelyoutofthewaywhenloweringtheengine.Carefullyworkthe
engine/transaxleassemblyintoposition.Then,installallmountingthroughbolts.Tightentheenginemountbolts,makingsurethereissomeclearanceintherubber
insulator.Removetheliftingslingandcrane.
21.Connectthefuelhosestothefuelfilter.Connectallcables,wires,andharnessconnectors.Connectthevacuumandairhosesthatrunfromthebodytotheengine

assembly.
22.Connectandadjusttheacceleratorcable.
23.Removetheragfromthetransaxleandinstallthespeedometerdrivepiniongear.Reconnectthespeedometercable.
24.ReconnecttheclutchcableandadjustitasdescribedinDriveTrain.
25.Makesurethesplinedendsofthehalfshaftsarecleanandthenreinsertthemintothetransaxle.Whentheyaresecurelylockedinplace,retorquethestrutnutswherethe
topsofthestrutsarefastenedtothebody.RefertoDriveTrainforadditionaldetails.
26.InstallnewtransmissionfluidofthespecifiedtypeandoftheamountspecifiedinGeneralInformation&Maintenance.
27.InstallbothballjointswithnewnutsandtorquethemasdescribedinBrakes.
28.Connecttheautomatictransaxlecontrollinkagetothetransaxle.Ifthecarhasamanualtransaxle,connectthecontrolrodlinksupportrodtothetransaxle.
29.Connecttheheaderpipetotheexhaustmanifold.
30.Bolttheairconditionercompressorandidlerpulleybrackettothecylinderblock.Installthecompressordrivebelt.
31.Installthepowersteeringpump,ifthecarhaspowersteering.Refillthepumpwithapprovedfluid.
32.Installtheradiatorandcoolingfan,andreconnectthefanelectricalconnector.Refillthecoolingsystemwith50/50ethyleneglycol/watermix.
33.Removetheraginstalledintotheairhornorthrottlebodyandinstalltheaircleanerandrelatedhoses.
34.Installthebatterysupportbracketandthebattery.Whenyouaresurethatallelectricalconnectionsaresafelyreconnected,reconnectthebatterycables.
35.Installthehoodwithboltsloose.Alignitwiththemarksmadeearlierandthentorquetheboltsto15ft.lbs.(20Nm).
36.BleedthefuelsystemasoutlinedinFuelSystem.
37.Starttheengine,checkforleaks,bleedthecoolingsystem,andrecheckandifnecessaryrefillallfluidreservoirs.

198790FuelInjectedEngines
SeeFigures9,10,11,12,13,14,15,16,17and18

Fig.Fig.9:ExplodedviewofoutercomponentsCA16DEandCA18DEengines

Fig.Fig.10:ExplodedviewofinternalcomponentsCA16DEandCA18DEengines

Fig.Fig.11:ExplodedviewofoutercomponentsintakesideGA16iengine

Fig.Fig.12:ExplodedviewofoutercomponentsexhaustsideGA16iengine

Fig.Fig.13:Enginemounting4WDSentra

Fig.Fig.14:DonotloosenthispowervalveadjustingscrewontheCA16DEorCA18DEengine.Thisscrewisadjustedatthefactory

Fig.Fig.15:Typicaltransaxlelinkageattachingpoints

Fig.Fig.16:Typicalrearenginemount

Fig.Fig.17:Typicalleftsideenginemount

Fig.Fig.18:Pryingbackonthehalfshafttoremoveitfromthetransaxle.Usecarenottodamagetheseal
Thisprocedureisfor198790CA16DE,CA18DE,E16iandGA16ifuelinjectedmodels.Carburetedanddieselengineproceduresfor1987modelscanbefoundearlierinthis
section.
TheGA16ienginecannotberemovedseparatelyfromthetransaxle.Evenontheothermodels,itisrecommendedthattheengineandtransaxleberemovedasaunit,then
separatedafterremoval.Ifequippedwith4WD,removetheengine,transaxleandtransfercasetogether.
1.Markthehoodhingerelationshipandremovethehood.
2.Releasethefuelsystempressure,disconnectthenegative()batterycableandraiseandsupportthevehiclesafely.
3.Drainthecoolingsystemandtheengineoil.

CAUTION
Whendrainingenginecoolant,keepinmindthatcatsanddogsareattractedtoethyleneglycolantifreezeandcoulddrinkanythatisleftinanuncoveredcontainerorinpuddles
ontheground.Thiswillprovefatalinsufficientquantity.Alwaysdraincoolantintoasealablecontainer.Coolantshouldbereusedunlessitiscontaminatedorisseveralyears
old.

4.Removetheaircleaneranddisconnectthethrottlecable.
5.Disconnectorremovethefollowing:

Drivebelts
Ignitionwirefromthecoiltothedistributor
Ignitioncoilgroundwireandtheenginegroundcable
Blockconnectorfromthedistributor
Fusiblelinks
Engineharnessconnectors
Fuelandfuelreturnhoses
Upperandlowerradiatorhoses
Heaterinletandoutlethoses
Enginevacuumhoses
Carboncanisterhosesandtheairpumpaircleanerhose
Anyinterferingengineaccessory:powersteeringpump,airconditioningcompressororalternator
Driveshaftfromtransfercase.

Makesuretomatchmarkthedriveshaftflanges.
6.Removetheairpumpaircleaner.
7.Removethecarboncanister.
8.Removetheauxiliaryfan,washertank,grilleandradiator(withfanassembly).
9.Removetheclutchcylinderfromtheclutchhousingformanualtransaxles.

10.Removebothbufferrodswithoutalteringthelengthoftherods.Disconnectthespeedometercable.
11.Removethespringpinsfromthetransaxlegearselectorrods.
12.Installengineslingerstotheblockandconnectasuitableliftingdevicetotheslingers.Donottensiontheliftingdeviceatthispoint.
13.Disconnecttheexhaustpipeatboththemanifoldconnectionandtheclampholdingthepipetotheengine.
14.Removethelowerballjoint.
15.Drainthetransaxlegearoil.
16.Disconnecttherightandleftsidehalfshaftsfromtheirsideflangesandremovetheboltholdingtheradiuslinksupport.

Whendrawingoutthehalfshafts,itisnecessarytoloosenthestrutheadbolts.
17.Lowertheshifterandselectorrodsandremovetheboltsfromtheenginemountbrackets.Removethenutsholdingthefrontandrearenginemountstotheframe.
Disconnecttheclutchandacceleratorwiresandremovethespeedometercablewithitspinionfromthetransaxle.
18.Lifttheengine/transaxleassemblyupandawayfromthevehicle.

Toinstall:
19.Lowertheenginetransaxleassemblyintothevehicle.Whenloweringtheengineontotheframe,makesuretokeepitaslevelaspossible.
20.Checktheclearancebetweentheframeandclutchhousingandmakesuretheenginemountboltsareseatedinthegrooveofthemountingbracket.
21.Afterinstallingtheenginemounts,adjustandinstallthebufferrods.Onthe198892Sentra4WD:frontshouldbe3.503.58in.(8991mm),andtherear,3.903.98in.(99
101mm).
22.Tightentheenginemountboltsfirst,thenapplyaloadtothemountinginsulatorsbeforetighteningthebufferrodandsubmountingbolts.
23.Connecttheclutchandacceleratorwiresandremovethespeedometercablewithitspinionfromthetransaxle.
24.Raisetheshifterandselectorrodstotheirnormaloperatingpositions.
25.Connectthehalfshafts.
26.Connectthelowerballjoint.
27.Connecttheexhaustpipetothemanifoldconnectionandtheclampholdingthepipetotheengine.
28.Disconnecttheliftingdeviceandremovetheengineslingers.
29.Insertthespringpinsintothetransaxlegearselectorrods.
30.Connectthespeedometercable.
31.Mounttheclutchcylinderontotheclutchhousing.
32.Installtheauxiliaryfan,washertank,grilleandradiator(withfanassembly).
33.Installthecarboncanister.
34.Installtheairpumpaircleaner.
35.Installorconnectallhoses,belts,harnesses,connectorsandcomponentsthatwerenecessarytoremovetheengine.
36.Connectthethrottlecableandinstalltheaircleaner.
37.Fillthetransaxleandcoolingsystemtotheproperlevels.
38.Installthehoodandconnectthenegative()batterycable.
39.Makeallthenecessaryengineadjustments.Chargetheairconditioningsystem.Roadtestthevehicleforproperoperation.

1991941.6Land1991962.0LEngines
SeeFigures1922

Fig.Fig.19:ExplodedviewofoutercomponentsontheintakesideGA16DEengine

Fig.Fig.20:ExplodedviewofoutercomponentsontheexhaustsideGA16DEengine

Fig.Fig.21:ExplodedviewofoutercomponentsSR20DEengine

Fig.Fig.22:ExplodedviewofoutercomponentsexhaustsideSR20DEengine
Itisrecommendedthattheengineandtransaxleberemovedasaunit.Ifnecessary,theymaybeseparatedafterremoval.
The1.6L(GA16DE)enginecannotberemovedseparatelyfromthetransaxle.Removetheengineandthetransaxleasaunit.Ifequippedwith4WD,removetheengine,
transaxleandtransfercasetogether.
1.Markthehoodhingerelationshipandremovethehood.

2.Releasethefuelsystempressure,disconnectthenegative()batterycableandraiseandsupportthevehiclesafely.
3.Drainthecoolingsystemandtheengineoil.

CAUTION
Whendrainingenginecoolant,keepinmindthatcatsanddogsareattractedtoethyleneglycolantifreezeandcoulddrinkanythatisleftinanuncoveredcontainerorinpuddles
ontheground.Thiswillprovefatalinsufficientquantity.Alwaysdraincoolantintoasealablecontainer.Coolantshouldbereusedunlessitiscontaminatedorisseveralyears
old.

4.Removetheaircleaneranddisconnectthethrottlecable.
5.Disconnectorremovethefollowing:
A.Drivebelts.
B.Ignitionwirefromthecoiltothedistributor
C.Ignitioncoilgroundwireandtheenginegroundcable
D.Blockconnectorfromthedistributor
E.Fusiblelinks
F.Engineharnessconnectors
G.Fuelandfuelreturnhoses
H.Upperandlowerradiatorhoses
I.Heaterinletandoutlethoses
J.Enginevacuumhoses
K.Carboncanisterhosesandtheairpumpaircleanerhose
L.Anyinterferingengineaccessories:powersteeringpump,airconditioningcompressororalternator
M.Driveshaftfromtransferunitfor4WDvehicles.

Makesuretomatchmarkthedriveshaftflanges.
6.Removetheairpumpaircleaner.
7.Removethecarboncanister.
8.Removetheauxiliaryfan,washertank,grilleandradiator(withfanassembly).
9.Removetheclutchcylinderfromtheclutchhousingformanualtransaxles.
10.Removebothbufferrodswithoutalteringthelengthoftherods.Disconnectthespeedometercable.
11.Removethespringpinsfromthetransaxlegearselectorrods.
12.Installengineslingerstotheblockandconnectasuitableliftingdevicetotheslingers.Donottensiontheliftingdeviceatthispoint.
13.Disconnecttheexhaustpipeatboththemanifoldconnectionandtheclampholdingthepipetotheengine.
14.Removethelowerballjoints.
15.Drainthetransaxlegearoil.
16.Disconnecttherightandleftsidehalfshaftsfromtheirsideflangesandremovetheboltholdingtheradiuslinksupport.

Whendrawingoutthehalfshafts,itisnecessarytoloosenthestrutheadbolts.
17.Lowertheshifterandselectorrods,andremovetheboltsfromtheenginemountbrackets.Removethenutsholdingthefrontandrearenginemountstotheframe.
18.Disconnecttheclutchandacceleratorwiresandremovethespeedometercablewithitspinionfromthetransaxle.
19.Lifttheengine/transaxleassemblyupandawayfromthevehicle.

Toinstall:
20.Lowertheengine/transaxleassemblyintothevehicle.Whenloweringtheengineontotheframe,makesuretokeepitaslevelaspossible.
21.Checktheclearancebetweentheframeandclutchhousingandmakesuretheenginemountboltsareseatedinthegrooveofthemountingbracket.
22.Afterinstallingtheenginemounts,adjustandinstallthebufferrods.Thefrontshouldbe3.503.58in.(8991mm),andtherear3.903.98in.(99101mm).
23.Tightentheenginemountboltsfirst,thenapplyaloadtothemountinginsulatorsbeforetighteningthebufferrodandsubmountingbolts.
24.Connecttheclutchandacceleratorwiresandinstallthespeedometercablewithitspiniontothetransaxle.
25.Raisetheshifterandselectorrodstotheirnormaloperatingpositions.
26.Connectthehalfshafts.
27.Connectthelowerballjointsandinstallnewcotterpins.
28.Connecttheexhaustpipetothemanifoldconnectionandtheclampholdingthepipetotheengine.
29.Disconnecttheliftingdeviceandremovetheengineslingers.
30.Insertthespringpinsintothetransaxlegearselectorrods.
31.Connectthespeedometercable.
32.Mounttheclutchcylinderontotheclutchhousing.
33.Installtheauxiliaryfan,washertank,grilleandradiator(withfanassembly).
34.Installthecarboncanister.

35.Installtheairpumpaircleaner.
36.Installorconnectallhoses,belts,harnesses,connectorsandcomponentsthatwerenecessarytoremovetheengine.
37.Connectthethrottlecableandinstalltheaircleaner.
38.Fillthetransaxleandcoolingsystemtotheproperlevels.
39.Installthehoodandconnectthenegative()batterycable.
40.Makeallthenecessaryengineadjustments.Chargetheairconditioningsystem.Roadtestthevehicleforproperoperation.

1995961.6LEngine
SeeFigures19,20,21and22

Fig.Fig.24:HeightadjustmentofthebufferrodGA16DEengine
Theengineandtransaxleareremovedasoneunitfromtheundersideofthevehicle.

CAUTION
FuelinjectionsystemsremainunderpressureaftertheenginehasbeenturnedOFF.Properlyrelievefuelpressurebeforedisconnectinganyfuellines.Failuretodosomay
resultinfireorpersonalinjury.

1.Relievethefuelsystempressure.
2.Disconnectthenegativeandpositivebatterycables.
3.Removethebatteryandbatterytrayfromthevehicle.
4.Raiseandsafelysupportthevehicle.
5.Removebothfrontwheels.
6.Removetheengineundercoversandremovetheenginesidecovers.
7.Drainthecoolantfromtheradiatorandtheengineblock.

CAUTION
Whendrainingenginecoolant,keepinmindthatcatsanddogsareattractedtoethyleneglycolantifreezeandcoulddrinkanythatisleftinanuncoveredcontainerorinpuddles
ontheground.Thiswillprovefatalinsufficientquantity.Alwaysdraincoolantintoasealablecontainer.Coolantshouldbereusedunlessitiscontaminatedorisseveralyears
old.

8.Draintheengineoil.
9.Removetheaircleanerassemblyandremoveairduct.
10.Notethelocationsandremovethevacuumhoses.
11.Disconnecttheheaterhosesfromtheengine.
12.Ifequipped,disconnecttheA/Tcoolerhosesfromthetransaxle.
13.Disconnectthefuelhosesfromtheengine.
14.Notethelocationsanddisconnecttheharnessandwiringconnections.
15.Disconnectthethrottlecableandthecruisecontrolcable.
16.Ifequippedwithautomatictransaxle,disconnectthecontrolcable.
17.Removethecoolingfans,radiator,andtherecoverytank.
18.Removethefrontdriveshaftsfromthevehicle.
19.Removethefrontexhaustpipe.
20.Disconnectthecontrolrodandsupportrodfromthetransaxle.
21.Removethestartermotorandintakemanifoldsupportbrackets.
22.Removetheenginedrivebelts.
23.Removethealternatorandadjustingbrackets.
24.RemovethepowersteeringpumpandA/Ccompressor.Itisnotnecessarytodisconnectthelines.
25.Removethecylinderheadfrontmountingbracket.
26.Positionatransmissionjackunderthetransaxleandsupporttheenginewithengineslinger.
27.Removethecentercrossmember.
28.Onsomemodelsitmaybenecessarytoremovethefrontstabilizerbar.

29.Removetheenginemountingboltsfrombothsidesoftheengine.
30.Slowlylowerthejackingdevicesandremovetheengineandtransaxlefromthevehicle.

Toinstall:
31.Installtheengineandtransaxleassembly.
32.Installthemountingboltsonbothsidesoftheengine.
33.Forvehicleswithmanualtransaxles,adjusttheheightofthemountingbracket(bufferrod).Thedistancebetweenthetwothroughboltsshouldbe2.1262.205in.(54
56mm).
34.Installthecentercrossmemberandremovetheenginesupportjacks.Removetheengineslinger.
35.Ifremoved,installthefrontstabilizerbar.
36.Ifremoved,installthecylinderheadfrontmountingbracket.
37.InstallthepowersteeringpumpandA/Ccompressor.
38.Installthealternatorassembly.
39.Installandadjusttheenginedrivebelts.
40.Installthesupportbracketstothestartermotorandtheintakemanifold.
41.Connectthecontrolrodandsupportrodtothetransaxle.
42.Tightenthecontrolrodboltto1013ft.lbs.(1418Nm).Tightenthesupportrodboltto2635ft.lbs.(3547Nm).
43.Installthefrontexhaustpipe.
44.Installthefrontdriveshafts.
45.Installtherecoverytank,radiator,andthecoolingfans.
46.Ifequippedwithautomatictransaxle,connectandadjustthecontrolcable.
47.Connectthethrottlecableandthecruisecontrolcable.Adjustasnecessary.
48.Connecttheharnessandwiringconnections.
49.Usingnewclamps,connectthefuelhosestotheengine.
50.Ifremoved,connecttheA/Tcoolerhosestothetransaxle.
51.Usingnewclamps,connecttheheaterhosestotheengine.
52.Usingnotedlocations,connectthevacuumhoses.
53.Installtheaircleanerassemblyandconnecttheairduct.
54.Refilltheengineoilandcoolingsystem.
55.Installtheenginesidecoversandtheengineundercovers.
56.Installbothfrontwheels.
57.Installthebatterytrayandinstallthebattery.
58.Connectthepositiveandthenthenegative()batterycables.
59.Starttheengineandcheckforleaks.Makeallthenecessaryadjustments.

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