Hyundai Elantra 1993 User Manual
ENGINE
MECHANICAL
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GENERAL
ENGINE MOUNTING
ENGINE AND TRANSAXLE ASSEMBLY
TIMING BELT
CAMSHAFT AND ROCKER ARMS
CYLINDER HEAD AND VALVES
FRONT CASE, OIL PUMP AND COUNTER
BALANCE SHAFT
PISTON AND CONNECTING ROD
CRANKSHAFT, FLY WHEEL
CYLINDER
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......................................... 33
............................................. 38
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.......................................... 53
................................................... 58
BLOCK
..................................................................
2
15
18
21
45
63
20-2
GENERAL
SPECIFICATIONS
GENERAL
Description
General
Type
Number of cylinders
Bore
Stroke
Total displacement
Compression ratio
Firing order
Idle R.P.M
Ignition timing at idling speed
Valve timing
Intake valve
Opens (BTDC)
Closes (ABDC)
Exhaust valve
Opens (BBDC)
Closes (ATDC)
Cylinder head
Flatness of gasket surface
Flatness of manifold mounting
surface
Oversize rework dimensions of valve
seat hole
Intake
0.3 mm (0.912 in.) O.S.
0.6 mm (0.024 in.) O.S
Exhaust 0.3 mm (0.012 in.) O.S.
0.6 mm (0.024) O.S.
Oversize rework dimensions of valve
guide hole (both intake and exhaust)
0.05 mm (0.002 in.) O.S.
0.25 mm (0.010 in.) O.S.
0.50 mm (0.020 in.) O.S.
Camshaft
1.6L Eng.
Cam height
intake
Exhaust
Journal O.D.
Bearing oil clearance
End play
1.8L Eng.
Cam height
Intake
Exhaust
Journal O.D.
Bearing oil clearance
End play
Specification
Limit
In-line, Double Over Head Camshaft
4
1.6L Eng.
82.3 mm (3.240 in.)
75.0 mm (2.953 in.)
1595 cc (97.3 cu.in.)
9.2
1.8L Eng.
81.5 mm (3.209 in.)
88 mm (3.465 in.)
1836 cc (112.04 cu.in.)
9.2
1-3-4-2
750 ± 100
BTDC 5o ± 2
1.6L Eng.
o
16
o
48
o
43
o
17
Max. 0.05 mm (0.0020 in.)
0.15 mm (0.0059 in.)
rpm
o
700
±
100 rpm
1.8L Eng.
o
26
o
46
o
55
o
9
0.1 mm (0.0039 in.)
0.2 mm (0.008 in.)
35.300-35.325 mm (1.3898-1.3907 in.)
35.600-35.625
33.300-33.325
33.600-33.625
mm
(1.4016-1.4026 in.)
mm
(1.3110-1.3120 in.)
mm
(1.3228-1.3238 in.)
12.050-12.068 mm (0.4744-0.4751 in.)
12.250-12.268 mm (0.4823-0.4830 in.)
12.500-12.518 mm (0.4921-0.4928 in.)
35.200 mm (1.3858 in.)
34.700 mm (1.3661 in.)
34.907 mm (1.3743 in.) 34.407 mm (1.3546 in.)
26 mm (1.02 in.)
0.05-0.09 mm (0.0020-0.0035)
0.1-0.2 mm (0.004-0.008 in.)
35.493 mm (1.3974 in.)
35.200 mm (1.3858 in.)
34.993 mm (1.3777 in.)
34.700 mm (1.3661 in.)
26 mm (1.02 in.)
0.05-0.09 mm (0.0020-0.0035 in.)
0.1-0.2 mm (0.004-0.008 in.)
GENERAL
20-3
Description
Valve
Valve length
Intake
Exhaust
Stem O.D.
Intake
Exhaust
Face angle
Thickness of valve head (margin)
Intake
Exhaust
Valve stem to valve guide
clearance
Intake
Exhaust
Valve guide
Length
Intake
Exhaust
Service
size
Valve seat
Width of seat contact
Seat angle
Service size
Specification
Limit
109.5 mm (4.311 in.)
109.7 mm (4.319 in.)
6.565-6.580 mm (0.2585-0.2591 in.)
6.530-6.550 mm (0.2571-0.2579 in.)
45-45.5
1.0 mm (0.039 in.)
o
0.7 mm (0.028 in.)
1.5 mm (0.059 in.) 1.0 mm (0.039 in.)
0.020-0.047 mm (0.0008-0.0019 in.)
0.050-0.085 mm (0.0020-0.0033 in.)
0.10 mm (0.0039 in.)
0.15 mm (0.0059 in.)
45.5 mm (1.791 in.)
50.5 mm (1.988 in.)
0.05, 0.25, 0.50 mm
(0.002, 0.010, 0.020
0.9-1.3 mm (0.035-0.051 in.)
44-44.5
o
in.)
oversize
0.3 mm (0.012 in.), 0.6 mm (0.024 in.)
oversize
Valve spring
Free length
Load
Out of squareness
Cylinder block
Cylinder bore
Out-of-roundness and taper of
cylinder bore
Flatness of gasket surface
Piston
O.D.
Piston-to-cylinder clearance
Ring groove width
No. 1
No. 2
Oil
Service size
48.3 mm (1.902 in,)
300 N (66 lb)/40 mm (1.575 in.)
Less than 1.5
o
47.3 mm (1.862 in.)
4
82.30-82.33 mm (3.2402-3.2413 in.)[1.6L Eng.]
81.50-81.53 mm (3.2087-3.2098 in) [1.8L Eng.]
Less than 0.01 mm (0.0004 in.)
Less than 0.05 mm (0.0020 in.)
0.1 mm (0.0039 in.)
82.27-82.30 mm (3.2390-3.2402 in.)[1.6L Eng.]
81.47-81.50 mm (3.2075-3.2087 in.)[1.8L Eng.]
0.02-0.04 mm (0.0008-0.0016 in.)
1.22-1.24 mm (0.0480-0.0488 in.)
1.52-1.54 mm (0.0598-0.0606 in.)
3.01-3.03 mm (0.1185-0.1193 in.)
0.25, 0.50, 0.75, 1.00 mm
(0.010, 0.020, 0.030, 0.039 in.) oversize
o
20-4 GENERAL
Description
Piston ring
Side clearance
No. 1, No. 2
End gap
1.6L Eng.
No. 1
No. 2
Oil ring side rail
1.8L Eng.
No.1,
No.2
Oil ring side rail
Service size
Connecting rod
Bend
Twist
Connecting rod big end to crankshaft
side clearance
Piston pin press-in load
Connecting rod bearing
Oil clearance
Crankshaft main bearing
Oil clearance
Crankshaft
Pin O.D.
Journal O.D.
Out-of-roundness of journal and pin
Taper of journal and pin
End play
Specification
0.03-0.07 mm (0.0012-0.0028 in.)
0.25-0.40 mm (0.0098-0.0157 in.)
0.35-0.50 mm (0.0138-0.0197 in.)
0.20-0.70 mm (0.0079-0.0276 in.)
0.25-0.40 mm (0.098-0.0157 in.)
0.45-0.60 mm (0.0177-0.0236 in.)
0.20-0.70 mm (0.0079-0.0276 in.)
0.25, 0.50, 0.75, 1.00 mm
(0.010, 0.020, 0.030, 0.039 in.) oversize
0.05 mm (0.0020 in.)
0.1 mm (0.004 in.)
0.10-0.25 mm (0.0039-0.0098 in.)
7,500-17,500 N (1,653-3,858 lb)
0.022-0.05 mm (0.00086-0.0020 in.)
0.02-0.05 mm (0.0008-0.0020 in.)
45 mm (1.77 in.)
57 mm (2.24 in.)
Less than 0.015 mm (0.0006 in.)
Less than 0.005 (0.0002)
0.05-0.18 mm (0.0020-0.0071 in.)
Limit
0.1 mm (0.004 in.)
0.8 mm (0.031 in.)
0.8 mm (0.031 in.)
1.0 mm (0.039 in.)
0.8 mm (0.031 in.)
0.8 mm (0.031 in.)
1.0 mm (0.039 in.)
0.4 mm (0.0157 in.)
0.1 mm (0.004 in.)
0.1 mm (0.004 in.)
0.25 mm (0.0098 in.)
Flywheel
Runout
Oil pressure at curb idle speed
[Oil tempreature is 75 to 90°C (167 to 194oF)]
Oil pump
Tip clearance
Drive gear
Driven gear
Side clearance
Drive gear
Driven gear
Relief spring
Free length
Load 161 N (13.5 lb)]
80 kPa (11.4 psi) or more
0.16-0.21 mm (.0.0063-0.0083 in.)
0.13-0.18 mm (0.0051-0.0071 in.)
0.08-0.14 mm (0.0031-0.0055 in.)
0.06-0.12 mm (0.0024-0.0047 in.)
46.6 mm (1.835 in.)
40.1 mm (1.579 in.)
0.13 mm (0.0051 in.)
0.25 mm (0.0098 in.)
0.25 mm (0.0098 in.)
0.25 mm (0.0098 in.)
0.25 mm (0.0098 in.)
GENERAL
20-5
Description
Right counter balance shaft
Front journal diameter
Rear journal diameter
Oil clearance
Front
Rear
Left counter balance shaft
Front journal diameter
Rear journal diameter
Oil clearance
Front
Rear
NOTE
O.D. = Outer Diameter
I.D. = Inner Diameter
O.S. = Oversize Diameter
U.S. = Undersize Diameter
Specification
41.959-41.975 mm (1.6519-1.6526 in.)
40.951-40.967 mm (1.6122-1.6129 in.)
0.020-0.0061 mm (0.0008-0.0024 in.)
0.050-0.091 mm (0.0020-0.0036 in.)
18.467-18.480 mm (0.7270-0.7276 in.)
40.959--40.975 mm (1.6126-1.6132 in.)
0.020-0.054 mm (0.0008-0.0021 in.)
0.042-0.083 mm (0.0017-0.0033 in.)
Limit
GENERAL
TIGHTENING TORQUE
Engine mount bracket nut and bolt
Engine mount insulator nut (large)
Engine mount insulator nut (small)
Front roll stopper insulator nut
Rear roll stopper insulator nut
Fuel high pressure hose to delivery pipe
Accelerator cable adjusting bolt
Front engine support bracket bolt
Front exhaust pipe support bracket bolt
Left engine support bracket bolt
Front roll stopper bracket bolt
Rear roll stopper bracket bolt
Engine mount bracket to bracket
Front engine support bracket to bracket
Air conditioner compressor to bracket
Power steering oil pump to bracket
Front exhaust pipe to exhaust manifold
Rocker cover bolt
Center cover bolt
Camshaft sprocket bolt
Camshaft bearing cap bolt
Crank angle sensor nut
Throttle body stay
Air cleaner body installation bolt
Crankshaft sprocket bolt
Crankshaft pulley to crankshaft sprocket
Cylinder head bolt (cold engine)
Intake manifold stay
Tension rod to bracket
Tension pulley bracket bolt
Auto tensioner bolt
Tensioner pulley bolt
Idle pulley bolt
Front exhaust pipe clamp bolt
Nm
50-65
90-110
45-60
45-60
45-60
4-6
4-6
50-70
30-42
30-42
55-75
110-130
17-26
17-26
23-27
45-55
30-40
2.5-3.5
2.5-3.5
80-100
19-21
10-13 100-130 7-9
15-22 150-220
8-10 80-100 6-7
110-130 1100-1300
20-30 200-300 14-22
105-115 1050-1150 76-83
25-30 250-300
35-55
17-26 170-260 12-19
20-27
43-55
30-42
20-30
kg.cm
500-650
900-1100
450-600
450-600
450-600 33-43
40-60 3-4
40-60 3-4
500-700
300-420
300-420
550-750
1100-1300
170-260
170-260
230-270
450-550
300-400 22-29
25-35
25-35 2-3
800-1000 58-72
190-210 14-15
350-550 25-40
200-270
430-550
300-420
200-300 14-22
Ib.ft
36-47
65-80
33-43
33-43
36-51
22-30
22-30
40-54
80-94
12-19
12-19
17-20
32.4-39.6
2-3
11-16
80-94
18-22
14-20
31-40
22-30
GENERAL
20-7
Oil pan
Oil pan drain plug
Oil screen
Oil pump sprocket bolt
Oil pressure switch
Oil filter bracket bolt
Oil pump cover bolt
Oil seal case bolt
Plug cap
Front case bolt
M8x30
except M8 x 30
Drive gear bolt
Water pump pulley bolt
Timing belt upper cover
Timing belt lower cover
Relief plug
Flywheel
Drive plate
Timing belt rear right cover
Timing belt rear left cover (lower)
-bolt also securing left engine support bracket
Timing belt rear left cover (upper)
Connecting rod cap bolt
Crankshaft bearing cap bolt
Engine hanger
Nm
6-8
35-45
15-22 150-220 11-16
50-60
8-12
15-22 150-220 11-16
15-18 150-180 11-13
10-12 100-120 7-9
20-27
27-34
20-27 200-270 14-20
34-40 340-400 25-29
8-10
10-12 100-120 7-9
10-12 100-120 7-9
40-50 400-500 29-36
130-140 1300-1400
130-140 1300-1400
10-12 100-120
30-42
10-12 100-120 7-9
50-53 500-530 36-38
65-70
12-15 120-150
kg.cm
60-80
350-450
500-600
80-120
200-270
270-340
80-100 6-7
300-420
650-700
Ib.ft
4-6
25-33
36-43
6-8
14-20
20-26
94-101
94-101
7-9
22-30
47-51
9-11
20-8
SPECIAL TOOLS
GENERAL
Tool
(Number and name)
09214-32000
Crankshaft front oil seal
installer
09214-32100
Crankshaft front oil seal guide
09221-21000
Camshaft oil seal installer
09221-21100
Camshaft oil seal guide
Illustration
Use
Installation of the crankshaft front oil seal
(use with 09214-32100)
Installation of the crankshaft front oil seal
(use wiht 09214-32000)
Installation of the camshaft oil seal (use
with 09221-21100)
Used as a guide when pressing in the
camshaft oil seal
(use with 09221-21000)
09221-32001
Cylinder head bolt wrench
09222-28000
Valve spring compressor
09222-28100
Valve spring compressor holder
09222-28200
Valve stem oil seal installer
Removal and tightening of the cylinder
Removal and installation of the inlet or
exhaust valve
Installation of the valve stem oil seal
GENERAL
20-9
20-10
TROUBLESHOOTING
GENERAL
Symptom
Low compression
Oil pressure drop
High oil pressure
Excessive engine rolling and
vibration
Probable cause
Blown cylinder head gasket
Worn or damaged piston rings
Worn piston or cylinder
Worn or damaged valve seat
Low engine oil level
Faulty oil pressure switch
Clogged oil filter
Worn oil pump gears or cover
Thin or diluted engine oil
Oil relief valve stuck (open)
Excessive bearing clearance
Oil relief valve stuck (closed)
Loose engine roll stopper (front, rear)
Loose transaxle mount bracket
Loose engine mount bracket
Loose center member
Broken transaxle mount insulator
Broken engine mount insulator
Broken engine roll stopper insulator
Remedy
Replace gasket
Replace rings
Repair or replace piston
and/or cylinder block
Repair or replace valve
and/or seat ring
Check engine oil level
Replace
Replace
Replace
Change and determine cause
Repair
Replace
Repair
Re-tighten
Re-tighten
Re-tighten
Re-tighten
Replace
Replace
Replace
Noisy valves
Connecting rod and/main
bearing noise
Timing belt noise
Thin or diluted engine oil (low oil pressure)
Worn or damaged valve stem or valve guide
Insufficient oil supply
Thin or diluted engine oil
Excessive bearing clearance
Incorrect belt tension
Change
Replace
Check engine oil level
Change and determine cause
Replace
Adjust belt tension
GENERAL
ENGINE [1.6L/1.8L Engine]
CHECKING ENGINE OIL
Refer to the page 10-8
REPLACING OIL FILTER
Refer to the page 10-9
CHANGING ENGINE OIL
Refer to the page 10-8
CHECKING COMPRESSION PRESSURE
1.
Before checking compression, check the engine oil level. Make
sure the starter motor and battery are in normal operating
condition.
2. Start the engine and wait until engine coolant temperature
reaches 80-95°C (176-205°F)
3. Stop the engine and disconnect the spark plug cables.
4. Remove the spark plugs.
5.
Crank the engine to remove any foreign objects in the cylinders.
6. Attach the compression gauge to the spark plug hole.
7.
Depress the accelerator pedal to fully open the throttle.
8. Crank the engine and read the gauge.
20-11
Limit : 12.0 kg/cm2 (1.18 MPa, 171 psi)
[250-460 rpm]
9. Repeat steps 6 through 8 on all cylinders, making sure that
the pressure differential for each of the cylinders is within the
specified limit.
Limit : Max. 1.0 kg/cm2 (100 kpa, 14 psi) between cylinders
10. lf a cylinder’s compression or pressure differential is below the
specification, add a small amount of oil through the spark plug
hole and repeat steps 6 through 9.
1)
If the addition of oil brings the compression up, it is possible
that there is wear between the piston ring and cylinder wall.
2)
If compression remains the same, valve seizure, poor valve
seating or a compression leak from the cylinder head gasket
are all possible causes.
Tightening torque
Spark
plug
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-30 Nm (200-300 kgcm, 15-21 Ib.ft)
20-12
GENERAL
DRIVE BELTS TENSION ADJUSTMENT
1.
Check that the belts are not damaged and are properly fit into
the pulley grooves.
CAUTION
1. When installing the V-ribbed belt, check that the Vribs are properly in alignment.
2.
If noise or slippage is detected, check the belt for wear,
damage, or breakage on the pulley contact surface, and
check the pulley for scoring. Also check for the proper
belt deflection measurement.
2.
Apply 100 N (22 Ibs.) force to the belt back midway between the
pulleys as shown in the illustration, measure the amount of
deflection with a tension gauge.
Standard value :
NOTE
1. The belt tension must be measured between the specified pulleys.
2. When a new belt is installed, adjust the tension to the
center of the standard range indicated under “New”.
And then let the engine idle for 5 minutes or more, and
check the standard value indicated under “Inspection”.
3. When adjusting a belt which has been used or a belt newly
installed after 5 minutes or more of operation, refer to the
standard value indicated under “Used”.
4. Refer to the standard value indicated under “Inspection”
for periodic inspections.
Type A tension gauge
Do not let the dial section of the tension gauge contact other objects
during measurement.
GENERAL
Type B tension gauge
1. When measuring, be sure to turn reset button in the arrow
direction to set the gauge needle to the RESET position.
2.
If the tension gauge is removed from the belt, the needle will still
indicate the tension. Read the tension after removing the gauge.
Alternator Belt Adjustment
CAUTION
If the belt is too loose,
ture wear. If the belt is too tight, the water pump bearing
or the alternator will get damaged.
1.
Loosen the alternator nut “A” and the tension adjuster lock bolt
"B".
2.
Using the tension adjuster bolt, adjust the belt tension to
specification.
3. Tighten the adjuster lock bolt “B”.
4. Tighten the alternator nut “A”.
5.
Check the tension or the deflection of belt, readjust if necessary.
Tightening torque
Alternator nut
Adjuster lock
Tension adjuster bolt.
there will cause noise or prema-
A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-25 Nm (200-250 kg.cm, 14-18 Ib.ft)
bolt
B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-15 Nm (120-150 kg.cm, 9-11 Ib.ft)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-12 Nm (80-120 kg.cm, Ib.ft)
20-13
CAUTION
Note that 1.6L and 1.8L Engine V-ribbed velts are different in length.
Standard Value
1.6L Eng.
1.8L Eng.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
980±5 mm
990±5
Power Steering Oil Pump Belt Adjustment
1.
Loosen the adjustment bolt of the power steering oil pump.
mm
20-14
2.
Adjust the deflection or the tension of the power steering pump
to specification.
3. Tighten the adjustment bolt.
4. Crank the engine one or more revolutions.
5. Check the belt deflection, readjust if necessary.
GENERAL
Air Conditioner Compressor Belt Adjustment
I.
Loosen the tension pulley adjustment bolt A.
2. Adjust the belt deflection with adjustment bolt B.
3. Tighten the fixing bolt A.
4. Re-check the belt deflection and re-adjust, if necessary.
NOTE
Before re-checking, crank the engine one or more
revolutions.
Lash Adjusters Check
If an abnormal noise is heard from the lash adjusters (tappets),
check as follows;
1. While installed to the cylinder head, press the part where the
rocker arm contacts the lash adjuster at the very top. If the
adjuster is normal, the part pressed will feel very hard.
2.
If it easily moves all the way downward when pressed, there is
a malfunction of the lash adjuster and it should be replaced with
a new one.
3.
If it feels spongy or elastic, probably oil with air mixed in it has
entered the lash adjuster, so follow the steps below:
o
Check whether the amount of oil is too much or is not
enough.
o
Check whether the cause of air becoming mixed into the oil
is a damaged oil screen or oil screen gasket. After repairing
the cause of the air leak, warm up the engine and then drive
the vehicle at low speed for a while.
Stop the engine and leave it off for a few minutes; then restart the engine and drive at low speed. Repeat this procedure several times during the course of about one hour so as
to remove the air from the oil.
ENGINE MOUNTING
ENGINE MOUNTING
20-15
ENGINE MOUNTING
REMOVAL
Attach an engine hoist to the engine hooks, and raise just enough
so that there is no pressure on the insulators.
Engine Mounting
1. Remove the engine mount insulator bolts.
2.
Remove the engine mount bracket from the engine.
Transaxle Mounting
1. For vehicles with a 5-speed manual transaxle, remove the
select control valve.
2. Remove the transaxle mount bolt.
3.
Detach the cap from the inside of the right fender shield, remove
the transaxle mounting bolts.
4. Remove the transaxle bracket.
Front Roll Stopper
Remove the front bracket from the center member.
ENGINE MOUNTING
Rear Roll Stopper
Remove the rear roll stopper from the center member.
Center member
1. Remove the under cover (R-H.).
2. Remove the front roll stopper mounting bolts.
3. Remove the rear roll stopper mounting bolts.
4. Remove the center member from the body.
20-17
INSPECTION ITEMS
Transaxle mounting
Front roll stopper
Engine mounting
Rear roll stopper
Center menber
20-18
ENGINE AND TRANSAXLE ASSEMBLY
ENGINE AND TRANSAXLE ASSEMBLY
REMOVAL
1. Remove the battery.
2. Detach the air cleaner.
3. Disconnect the connectors for the backup lamp and engine
harness.
4.
For a vehicle with a 5-speed manual transaxle, disconnect the
select control valve connector.
5.
Disconnect the connectors for the alternator harness and the oil
pressure gauge wiring.
6. Drain the engine coolant.
7.
For vehicles with an automatic transaxle, disconnect the transaxle
oil cooler hoses.
NOTE
When disconnecting the hoses, make identification marks
to avoid making any mistakes in reconnecting them.
CAUTION
Be careful not to spill any of the oil or fluid out of the
hoses, and plug the openings to prevent the entrance of
foreign material.
8. Disconnect the radiator upper and lower hoses on the engine
side, and then remove the radiator assembly.
9.
Disconnect the high tension cable from the ignition coil section.
10. Disconnect the engine ground.
11 .Disconnect the brake booster vacuum hose.
12. Remove the main fuel line, and the return and vapor hoses from
the engine side.
CAUTION
To reduce the residual pressure in the hoses, refer to
Group Fuel System “Fuel filter replacement”.
13. Disconnect the heater hoses (inlet and outlet) on the engine
side.
14. Disconnect the accelerator cable at the engine side.
15. For vehicles with a manual transaxle, remove the clutch cable
from the transaxle.
16. For vehicles with an automatic transaxle, remove the control
cable from the transaxle:
17. Disconnect the speedometer cable from the transaxle.
18. Disconnect the air conditioner from the mounting bracket.
ENGINE AND TRANSAXLE ASSEMBLY 20-19
19. Jack up the vehicle.
20. Drain the transaxle oil (or fluid).
21. Disconnect the front exhaust pipe from the manifold.
NOTE
Use wire to suspend the exhaust pipe from the bottom
of the vehicle.
22. For vehicles with a manual transaxle, remove the shift control
rod and extension rod.
23. Remove the lower arm ball joint bolts and the stabilizer bar at the
point where it is mounted to the lower arm.
24. Remove the drive shafts from the transaxle case.
CAUTION
1)
Plug the holes of the transaxle case to prevent entry of
foreign material.
2) Install new circlips on the drive shafts when
reassembling.
25. Hang the lower arm and drive shaft from the body with a string.
26. Attach a cable to the engine, and use a chain hoist to lift the
engine only enough to pull cable tight.
27. Remove the front roll stopper.
28. Separate the rear roll stopper.
29. Remove the engine mounting insulator bolts.
30. Remove the engine mounting bracket from the engine.
31. Slowly raise the engine (to the extent that the engine and
transaxle weights are not applied to the mounting portions) and
temporarily hold it in the raised condition.
CAUTION
Check that all of the cables, hoses, harnesses, connectors etc. are disconnected from the engine.
32. Remove the caps from inside the right fender shield and remove
the transaxle mount bracket bolts.
33. Remove the left mount insulator bolt.
34. While directing the transaxle side downward, lift the engine and
transaxle assembly up and out of the vehicles.
20-20
ENGINE AND TRANSAXLE ASSEMBLY
INSTALLATION
1.
While checking the connections of the harnesses, pipes, hoses,
etc., and making sure that none of them are being caught,
damaged, etc., install the engine and transaxle assembly.
2.
Install the mounting stoppers with the arrows on them pointing
in the direction shown.
3.
When the engine and transaxle assembly is in place temporarily
tighten the front roll stopper.
4.
The front and rear center member rubber bushings and collars
are different.
5.
After the weight of the engine and transaxle assembly has been
put on each insulator, tighten to specified torque.
6.
Reassemble all of the components removed during disassembly. Be especially careful to properly secure all components,
including fuel, electrical and fluid pipe connections.
7. Refill the coolant and check for leaks.
8.
Refill the transaxle fluid, test its operation, and check for leaks.
9.
Check the operation of the transaxle control cable and accelera-
tor cable. Adjust as necessary.
10. Check for proper operation of each of the various gauges.
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