Engine: Removal & Installation Geo Prizm II

Removal

1. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-49089-S02854286982001011500000) . Disconnect battery cables, and remove battery. Remove hood.
2. Drain engine oil and cooling system. Disconnect necessary coolant hoses and fuel lines. Remove air intake duct and control cables from throttle body. Remove air cleaner.
3. Disconnect necessary vacuum hoses. Disconnect electrical connections at A/C SV valve, MAP sensor, data link connector, A/C triple switch and engine ground wires. Remove cruise control actuator (if equipped). On A/T models, disconnect shift cable and oil cooler lines from transaxle. On M/T models, disconnect clutch and shift control cables.
4. On all models, disconnect speedometer cable at transaxle. Remove coolant recovery bottle and bracket. Remove radiator and cooling fan. Remove power steering pump and A/C compressor (if equipped) with hoses attached and set aside.
5. Remove knee bolster, glove box and center console from vehicle. Remove radio. Remove one bolt and set aside left-side carpet bracket. Remove cruise control module mounting bolts and set aside. Disconnect PCM. From engine compartment side, pull wiring harness and grommet through firewall.
6. Raise and support vehicle. Remove lower engine covers. Drain transaxle fluid. Disconnect exhaust pipe at exhaust manifold. Disconnect oxygen sensor connector. Remove front tire and wheel assemblies.
7. Remove tie rod nuts from left and right steering knuckle. Separate tie rods from steering knuckles. Remove lower ball joints from steering knuckles. Separate lower control arms from steering knuckles.
8. Using a pry bar or large screwdriver, pry axle shafts from transaxle case. Support engine with hoist. Remove bolt from engine mount near timing belt cover. Remove transaxle mount bolts. If necessary, remove crossmember located below transaxle. Remove engine and transaxle. Separate engine from transaxle.

Installation

1. To install, reverse removal procedure. Tighten all fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-49089-S21496165542001011500000) at the end of this article.
2. Adjust all control cables. Adjust fluid levels. On A/T models, fill transaxle with Dexron-II. On M/T models, fill transaxle with SAE 75W-90 GL-5 gear lubricant.

1. Disconnect negative battery cable. Remove air intake ducting. Disconnect vacuum hoses from fuel pressure regulator, brake booster and A/C idle actuator. Remove EGR SV valve.
2. Remove intake manifold brace. Disconnect fuel hose from fuel pressure regulator. Remove metal vacuum lines from intake manifold. Remove EGR valve and vacuum modulator.
3. Disconnect and remove necessary vacuum and electrical connections from throttle body. Remove throttle body from upper intake chamber. Remove fuel inlet hose. Remove upper intake chamber cover. CAUTION: Do not drop fuel injectors when removing fuel rail. Damage to injectors may result.
4. Remove electrical connections from fuel injectors. Remove fuel rail mounting bolts and remove fuel rail with injectors. Remove 4 insulators and 2 spacers from intake manifold. Remove intake manifold mounting nuts and ground strap. Remove intake manifold from cylinder head.

1. Install NEW intake manifold gasket. Install NEW injector insulators in intake manifold. Install fuel rail with injectors, ensure injectors rotate freely. If injectors do not rotate freely "O" rings may not be properly installed.
2. To complete installation, reverse removal procedure. Tighten bolts/nuts to specification. See «TORQUE SPECIFICATIONS»(ref-49089-S21496165542001011500000) at the end of this article. Fill cooling system.

1. Disconnect negative battery cable. Remove heat shield from exhaust manifold. If necessary, disconnect oxygen sensor wiring connector. Remove exhaust manifold brace.
2. Remove warm-up catalyst (California models). Disconnect exhaust pipe from exhaust manifold. Remove exhaust manifold bolts/nuts, exhaust manifold and gasket.

To install, reverse removal procedure. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS .

1. Remove intake and exhaust manifolds. See «INTAKE MANIFOLD»(ref-49089-S03416794202001011500000) and «EXHAUST MANIFOLD»(ref-49089-S18996691142001011500000) under REMOVAL & INSTALLATION.
2. Disconnect necessary coolant hoses and vacuum lines. Remove EGR valve and lines.
3. Disconnect electrical connections at distributor. Remove distributor cap. Mark rotor-to-distributor housing position and housing-to-cylinder head position. Remove retaining bolt, and remove distributor assembly.
4. Remove timing belt and camshafts. See «TIMING BELT»(ref-49089-S42399268262001011500000) and CAMSHAFT under «REMOVAL & INSTALLATION»(ref-49089-S17065116592001011500000).
5. Loosen cylinder head bolts in reverse of tightening sequence. (Scheme 4) Remove bolts, note location and length of cylinder head bolts for installation reference. Remove cylinder head and gasket.

Scheme 4

1. If spark plug tubes were removed or NEW cylinder head is installed, install spark plug tubes before head is installed on engine block. Use 3-Bond (1324) adhesive or equivalent to coat bore of cylinder head for spark plug tube. Using Press, install spark plug tubes into bores until tube protrudes 1.843-1.874" (46.8-47.6 mm) from top horizontal surface of cylinder head. (Scheme 5)
2. Before installing cylinder head bolts, apply light coat of engine oil to threads and below bolt heads. Tighten cylinder head bolts in sequence. (Scheme 4) Tighten bolts in several steps to specification. See «TORQUE SPECIFICATIONS»(ref-49089-S21496165542001011500000).
3. If cylinder head components were serviced, check valve clearance. See «VALVE CLEARANCE ADJUSTMENT»(ref-49089-S07639253242001011500000) under ADJUSTMENTS.
4. Ensure reference mark is aligned on distributor. If fuel injectors were removed from fuel rail, install NEW grommet and "O" ring on each fuel injector and insulators in intake manifold. Lubricate "O" ring with gasoline before installing fuel injector on fuel rail. CAUTION: Ensure fuel injector rotates smoothly on fuel rail and intake manifold after installation. If fuel injector does not rotate smoothly, check for improper seal of fuel injector on fuel rail and intake manifold.
5. Before installing valve cover, apply Sealant (1052751) at valve cover-to-camshaft bearing cap surfaces on front and rear camshaft bearing caps. Fill cooling system.

Scheme 5