## ENGINE MECHANICAL

### Engine

#### REMOVAL & INSTALLATION

##### 200SX and 240SX (Rear Wheel Drive Models)

The following procedure can be used on all years and models. Slight variations may occur due to extra connections, etc., but the basic procedure should cover all years and models. The engine and transmission are removed together as assembly and then separated when out of the car. Always observe the following cautions:

- Make sure the vehicle is on a flat and level surface and that wheels are tightly chocked. Use the chocks on both sides of the rear wheels on front wheel drive cars.
- Allow the exhaust system to cool completely before starting work to prevent burns and possible fire as fuel lines are disconnected.
- Release fuel pressure from the fuel system before attempting to disconnect any fuel lines.
- When lifting the engine out, guide it carefully to avoid hitting parts such as the master cylinder.
- Mount the engine securely and then release the tension of lifting chains to avoid injury as you work on the engine.

1. Mark the location of the hinges on the hood. Unbolt and remove the hood.
2. Disconnect the battery cables. Remove the battery.
3. Drain the coolant and automatic transmission fluid.
4. Remove the radiator and radiator shroud after disconnecting the automatic transmission coolant tubes.
5. Remove the air cleaner.
6. Remove the fan and pulley.
7. Disconnect:
   1. water temperature gauge wire;
   2. oil pressure sending unit wire;
   3. ignition distributor primary wire;
   4. starter motor connections;
   5. fuel hose;

      CAUTION
      On all fuel injected models, the fuel pressure must be released before the fuel lines can be disconnected. See the pressure releasing procedure under Gasoline Engine Fuel Filter in Section 1.

   6. alternator leads;
   7. heater hoses;
   8. throttle and choke connections;
   9. engine ground cable;
   10. thermal transmitter wire;
   11. wire to fuel cut-off solenoid;
   12. vacuum cut solenoid wire.

       NOTE: A good rule of thumb when disconnecting the rather complex engine wiring of today's cars is to put a piece of masking tape on the wire and on the connection you removed the wire from, then mark both pieces of tape 1, 2, 3, etc. When replacing wiring, simply match the pieces of tape.

       CAUTION
       On models with air conditioning, it is necessary to remove the compressor and the condenser from their mounts. DO NOT ATTEMPT TO UNFASTEN ANY OF THE AIR CONDITIONER HOSES. See Section 1 for additional warnings.

8. Disconnect the power brake booster hose from the engine.
9. Remove the clutch operating cylinder and return spring.
10. Disconnect the speedometer cable from the transmission. Disconnect the backup light switch and any other wiring or attachments to the transmission. On manual transmission models, remove the boot, withdraw the lock pin, and remove the lever from inside the car.
11. Detach the exhaust pipe from the exhaust manifold. Remove the front section of the exhaust system. Be careful not to break the retaining bolts to manifold. If the bolts or studs break in the manifold remove the manifold and drill and tap the hole.
12. Mark the relationship of the driveshaft flanges and remove the driveshaft.
13. Place a jack under the transmission. Remove the rear crossmember.
14. Attach a hoist to the lifting hooks on the engine (at either end of the cylinder head). Support the engine.

    NOTE: On 1984 and later 200SX models, do not loosen the front engine mounting insulator cover securing nuts. When the cover is removed, the damper oil will flow out and the mounting insulator will not function.

15. Unbolt the front engine mounts. Tilt the engine by lowering the jack under the transmission and raising the hoist. Remove the engine/transmission assembly from the vehicle.

    To install:

16. With the engine/transmission assembly mounted safely on the engine hoist slowly lower the engine/transmission assembly into place.

    NOTE: When installing the CA20E and CA18ET engines into 1984 and later 200SXs, the rear engine mounting bracket must be adjusted. Using the accompanying illustration as a guide, adjust the rear mounting stopper clearance (X in the illustration) to 13mm.

17. Support the transmission with a jack or equivalent until the crossmember is installed.
18. Tighten the front engine mounts. It may be necessary to lower or raise the engine hoist to correctly position the engine assembly to line up with the mount holes. Remove the engine hoist.
19. Install the crossmember then remove the jack or equivalent supporting the transmission.
20. Install the driveshaft in the correct marked position.
21. Reconnect the front exhaust system to the exhaust manifold. Be careful not to tighten retaining bolts to manifold to tight. If the bolts or studs break in the manifold remove the manifold and drill and tap the hole.
22. Reconnect all wiring at the transmission and the speedometer cable.
23. On manual transmission models, install the lever, lock pin and shift boot.
24. Install the clutch cylinder and return spring. Reconnect the power brake hose to the engine if so equipped.
25. Install all wiring, brackets, vacuum hoses and water hoses to the engine. Make sure all connections are tight and in the correct location. It is always a good idea to replace all the old water hoses, drive belts, clamps, spark plugs oil and oil filter when installing the engine.
26. Install the fan and fan pulley.
27. Install the radiator shroud than the radiator reconnect the transmission lines if so equipped.
28. Refill the radiator and all other fluid levels.
29. Install the air cleaner, battery and reconnect the battery cables.
30. Install the hood in the same location as you removed it from.
31. Check all fluids, start engine, let it warm up and check for leaks.
32. Road test vehicle after you are sure there are no leaks. Check vehicle for proper operation. Recheck all fluid levels.

    Fig. 1: Removing the engine assembly from the vehicle

    Fig. 2: Gearshift lever removal

    Fig. 3: On 1984 and later 200SX models, do not loosen the front engine mounting insulation cover securing nuts

    Fig. 4: When installing the 1984 and later 200sx engine, adjust the rear mounting stopper clearance (X) to 13mm

##### Stanza and Stanza Wagon(Front Wheel Drive Models)

The following procedure can be used on all years and models. Slight variations may occur due to extra connections, etc., but the basic procedure should cover all years and models. Refer to all " Engine Mounting'' illustrations.

CAUTION
On EFI equipped models, release the fuel pressure in the system before disconnecting the fuel lines. Situate the vehicle on as flat and solid a surface as possible. Place chocks or equivalent at front and rear of rear wheels to stop vehicle from rolling.

NOTE: The engine and transaxle must be removed as a single unit. The engine and transaxle is removed from the top of the vehicle. If equipped with 4WD remove the engine, transaxle and transfer case as an assembly.

1. Mark the location of the hinges on the hood. Remove the hood by holding at both sides and unscrewing bolts. This requires 2 people.
2. Disconnect the battery cables and remove the battery.

   Fig. 5: Procedure for tightening engine mounting bolts — Stanza

3. Drain the coolant from the radiator, then remove the radiator and the heater hoses.
4. Remove the air cleaner-to-rocker cover hose and the air cleaner cover, then place a clean rag in the carburetor or throttle body opening to keep out the dirt or any foreign object.

   NOTE: Disconnect and label all the necessary vacuum hoses and electrical connectors, for reinstallation purposes. A good rule of thumb when disconnecting the rather complex engine wiring of today's cars is to put a piece of masking tape on the wire and on the connection you removed the wire from, then mark both pieces of tape 1, 2, 3, etc. When replacing wiring, simply match the pieces of tape.

5. If equipped, disconnect the air pump cleaner and remove the carbon canister.
6. Remove the auxiliary fan, the washer tank and the radiator grille if necessary. Remove the radiator together with the fan motor assembly as a unit.
7. Remove the clutch control wire or cable from the transaxle. Remove the right and the left buffer rods but do not alter the length of these rods. Disconnect the speedometer cable from the transaxle and plug the hole with a clean rag.

   NOTE: Remove the EGR vacuum control valve with the bracket from the body.

8. If equipped with air conditioning, loosen the idler pulley nut and the adjusting bolt, then remove the compressor belt. Remove the compressor to one side and suspend on a wire. Remove the condenser and the receiver drier and place them on the right fender.

   NOTE: If equipped with AC, DO NOT ATTEMPT TO UNFASTEN ANY OF THE REFRIGERANT HOSES. See Section 1 for additional warnings and service procedures. If equipped with power steering, loosen the idler pulley nut and adjusting bolt, then remove the drive belt and the power steering pulley.

9. If equipped with a manual transaxle, disconnect the transaxle shifting rods by removing the securing bolts. If equipped with an automatic transaxle, disconnect the mounting bracket and the control wire from the transaxle.

   NOTE: On 4WD drive applications matchmark and remove the driveshaft from the transfer assembly.

10. Attach the engine sling at each end of the engine block. Connect a chain or cable to the engine slingers.
11. Unbolt the exhaust pipe from the exhaust manifold. There are 3 bolts which attach the pipe to the manifold and bolts which attach the pipe support to the engine.

    NOTE: Remove the tie rod ends and the lower ball joints. Disconnect the right and left side drive shafts from their side flanges and remove the bolt holding the radius link support. When drawing out the halfshafts, it is necessary to loosen the strut head bolts also be careful not to damage the grease seals.

12. Refer to Section 7, for the axle shaft, removal and installation procedures, then remove the axle shafts.
13. Remove the radius link support bolt, then lower the transaxle shift selector rods.
14. Unbolt the engine from the engine and the transaxle mounts.
15. Using an overhead lifting device, attach it to the engine lifting sling and slowly remove the engine and transaxle assembly from the vehicle.

    NOTE: When removing the engine, be careful not to knock it against the adjacent parts.

16. Separate the engine from the transaxle if necessary. Install all the necessary parts on the engine before lowering it into the vehicle, such as, spark plugs, water pump etc.

    To install:

17. Lower the engine and transaxle as an assembly into the car and onto the frame, make sure to keep it as level as possible.
18. Check the clearance between the frame and clutch housing and make sure that the engine mount bolts are seated in the groove of the mounting bracket.
19. Install the motor mounts, remove the engine sling and install the buffer rods, tighten the engine mount bolts first, then apply a load to the mounting insulators before tightening the buffer rod and sub-mounting bolts.
20. If the buffer rod length has not been altered, they should still be correct. Shims are placed under the engine mounts, be sure to replace the exact ones in the correct places.
21. Install the transaxle shift selector rods or cable and attaching parts.
22. Install the axle shafts and the attaching parts.

    NOTE: On 4WD drive applications install the driveshaft to the transfer assembly.

23. Install the exhaust pipe to the manifold, it is a good idea to replace the gasket for the exhaust pipe at this time.
24. Install clutch cable if so equipped and speedometer cable.
25. Install the condenser, receiver drier, air conditioning compressor, power steering pump and all drive belts.
26. Install the radiator with fan motor attached as assembly, radiator grille as necessary, washer tank and the auxiliary fan.
27. Install air pump cleaner, if so equipped and the carbon canister.
28. Install all other attaching parts such as brackets etc. and the air cleaner that were removed and connect all the vacuum hoses and the electrical connectors.
29. Connect the radiator and heater hoses and refill the system with the correct amount of antifreeze.
30. Install the battery and reconnect the battery cables.
31. Install the hood in the same location as you removed it from.
32. Fill and check all fluids, start engine, let it warm up and check for leaks.
33. Road test vehicle after you are sure there are no leaks. Check vehicle for proper operation. Recheck all fluid levels.