Powertrain with Automatic Transmission

Removal Warning The engine may be removed from the vehicle only together with the power unit (i.e., as an assembly with the transmission). The power unit is lowered and removed from under the vehicle. To remove the engine this way without obstruction, raise the vehicle to a height of at least 75 cm (from floor to front bumper) and support it on stands.

PROCEDURE

1. Park the vehicle on a firm, level surface. Chock the rear wheels and apply the parking brake. Raise the front of the vehicle and support it on stands.

2. Remove the front wheels.

3. Remove the screws and all engine undercovers.

4. Remove the hood (see subsection 13.7).

5. Drain the engine coolant.

6. Drain the transmission oil, install and tighten both plugs.

7. Drain the engine oil and remove the oil filter. Clean and tighten the drain plug.

8. Remove the battery.

9. Remove the expansion tank with bracket.

10. Remove the drive belts.

11. Remove the alternator.

12. On vehicles equipped with air conditioning, unbolt the compressor, move it aside and secure it. Do not disconnect the air conditioning hoses.

13. Remove the power steering pump (see subsection 12.15).

14. Remove the brake calipers, move them aside and secure them without disconnecting the hoses.

15. Disconnect the CV joints from the hubs.

16. Disconnect the drive shafts (see subsection 10.2).

17. Disconnect the gear selector cable.

18. Remove the side member.

19. Disconnect the exhaust pipe from the muffler.

20. Remove the radiator with the hoses and fans.

21. Disconnect the stabilizer bar (see subsection 12.6).

22. On carbureted engines, remove or disconnect the following parts and assemblies: – air cleaner; – fuel hoses; – throttle cable; – carburetor wiring; – vacuum booster hose, cooling system hoses and other sensor and valve hoses; – intake manifold stand; – exhaust gas sensor connector.

23. On fuel-injected engines, perform the following: – remove the air cleaner intake duct; – relieve the fuel system pressure, disconnect the fuel hoses from the throttle body; – disconnect the throttle cable; – disconnect the wiring harness connectors; – move the wiring harness away from the engine.

24. Disconnect all hoses from the intake manifold.

25. Remove the intake manifold stand.

26. Mark the positions and disconnect the heater hoses and cooling system hoses from the engine.

27. Disconnect the wiring harness connectors from the distributor, ignition coil and electronic ignition module. Release the wiring harness from the clamps on the cylinder head and move it aside. Remove the bolts and all ground wires from the cylinder head and intake manifold.

28. Disconnect the speedometer cable and wires from the transmission.

29. Attach the hoist to the cylinder head lifting eyes and take up the slack so that the hoist supports the weight of the powertrain.

30. Mark the position of the tie bolt (indicated by the arrow) on the front engine mount bracket, remove the tie bolt nut and pull out the bolt.

31. Remove the nut and pull out the rear mount tie bolt (indicated by the arrow). Remove the front mount and bracket.

32. Remove the right mount and rubber cushions.

33. Remove the left mount and rubber cushions.

34. Make sure that all parts, wires and hoses that could interfere with removal are disconnected, removed and moved aside.

35. Position a transmission jack under the engine and carefully lower the powertrain. It is advisable to perform this operation with an assistant, as the engine must be tilted slightly to avoid damaging the body.

36. Roll the powertrain out from under the vehicle.

Separating the Transmission from the Engine

PROCEDURE

1. Secure the removed powertrain with wooden blocks on a level surface.

2. Remove the starter motor.

3. Remove the oil pan cover and unbolt the first accessible torque converter bolt, then, turning the crankshaft, unbolt the remaining 3 bolts in turn.

4. Secure the torque converter with a length of metal strip bolted to one of the starter motor mounting holes.

5. Unbolt the transmission case mounting bolts from the engine, marking the position of each bolt.

6. Carefully remove the transaxle.

Installation

PROCEDURE

1. If the transaxle was removed from the engine, perform the operations described below in steps 1–6. If the transaxle was not removed, follow step 7 and onward.

2. Measure the distance from the torque converter mounting bolt holes to the transaxle case mating surface. When installed correctly, this distance must be at least 21.1 mm.

3. Install the dowel pins (if removed).

4. Carefully install the transaxle onto the engine using the guide pins and tighten the bolts to the specified torque.

5. Remove the torque converter retaining strap, align the torque converter holes with the holes in the drive plate, and install the mounting bolts.

6. Tighten the torque converter bolts to the specified torque, install the oil pan cover, and tighten the bolts.

7. Install the starter motor.

8. Position the powertrain under the vehicle and attach the hoist cable.

9. With an assistant, carefully lower the powertrain into the engine compartment.

10. Install the rubber cushions on the left powertrain mount bracket, making sure the cushion studs enter the bracket holes. Install the mount in place, tighten the mount bolts to the transaxle to the specified torque. Insert the through bolt and tighten the nut by hand.

11. Install the rubber cushions on the right suspension bracket from the body side, making sure the cushion studs enter the holes in the bracket. Install the mount on the bracket and tighten the bolts to the specified torque. Insert the through bolt and tighten the nut by hand.

12. Insert the rear mount through bolt and tighten the nut by hand.

13. Install the side member and tighten the bolts to the specified torque.

14. Install the front mount bracket and tighten the bolts. Insert the through bolt and tighten the nut by hand. Position the engine so the alignment marks on the through bolt, made during disassembly, line up, then tighten the nut.

15. Rock the powertrain and tighten the through bolts of the remaining mounts.

16. Further installation of the powertrain is performed in the reverse order of removal.

17. Make sure the wiring is routed along its original paths and secured with clips and brackets, and that all connectors are reconnected.

18. Replace the axle shaft seals and install the axle shafts.

19. Connect all cooling system hoses.

20. Adjust the throttle cable (see subsection 6.1.7).

21. Connect and adjust the gear selector and kick-down cables.

22. Install and adjust the drive belts.

23. Change the engine oil and transaxle oil.

24. Fill the engine with coolant.

25. Start the engine and check for leaks.