B. Remove Engine and Transmission Assembly
Remove Engine and Transmission Assembly to Replace All Engine Block and Head Core Plugs:NOTE:
Only those vehicles that have a leaking core plug as determined by the inspection in Section "A" require core plug replacement. Very few vehicles are expected to require this repair.
1. Remove the fuel pump relay from the power distribution center (PDC).
2. Start the engine and run it until it runs out of fuel and stops. Turn off the engine.
3. Install the fuel pump relay into the PDC.
4. With the ignition key in the OFF position, disconnect the battery.
Note:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure.
5. Disconnect the fuel line from the fuel rail.
6. Remove the pressure tester from the filler neck.
7. Raise the vehicle on a hoist.
8. Using a 3/8" drive, 19 mm socket, 3" extension, universal joint and another extension, open the radiator draincock to drain the coolant.
CAUTION:
Use care to avoid burns from hot coolant.
9. Remove the drain plug from the rear of the engine cylinder block (Figure 1) to drain the coolant from the engine.
CAUTION:
Use care to avoid burns from hot coolant.
10. Reinstall the rear cylinder block drain plug.
11. Lower the vehicle.
12. Remove the coolant from the coolant reserve tank using a suction gun.
13. Discharge the air conditioning system (if equipped).
14. Remove the upper radiator crossmember (Figure 4).
15. Remove the upper radiator hose.
16. Disconnect the radiator fan electrical connector.
17. Disconnect the automatic transmission hoses from the cooler. Plug the hoses.
18. Remove the lower radiator hose from the radiator.
19. Disconnect the engine block heater wire (if equipped).
20. Disconnect the air conditioning condenser lines from the condenser.
21. Lift the radiator and fan module from the engine compartment and set aside.
CAUTION:
Do not damage the radiator cooling fins or water tubes during removal.
22. Remove the bolt that holds the air inlet resonator to the intake manifold (Figure 5).
23. Loosen the clamp that holds the air inlet tube to the throttle body and then remove the resonator, inlet tube and air cleaner cover as an assembly.
24. Disconnect the coolant overflow hose from the engine filler neck and set the hose aside.
25. Disconnect the powertrain control module (PCM) connector.
26. Disconnect the positive battery cable.
27. Disconnect the black and gray 10-way connectors at the rear of the PCM.
28. Disconnect the black and gray connectors at the front of the transmission control module (TCM).
29. Disconnect the TCM connector.
30. Remove the TCM and bracket assembly.
31. Disconnect the four (4) transmission electrical connectors.
32. Disconnect the transmission cooler line from the transmission.
33. Disconnect the transmission shift linkage.
34. Disconnect the heater hoses from the engine. Mark the hoses front and rear to identify them for reassembly.
35. Disconnect the throttle body linkage.
36. Disconnect the brake booster vacuum hose from the intake manifold.
37. Disconnect the vapor canister hose.
38. Disconnect the engine ground strap from the strut tower.
39. Disconnect the low pressure line from the A/C compressor.
40. Loosen the power steering pump pivot bolt (Figure 6)
41. Raise the vehicle on an appropriate hoist.
42. Remove the right inner splash shield.
43. Loosen the power steering pump locking bolts (Figure 6) and remove the power steering pump belt.
44. Loosen the air conditioning compressor and generator drive belt idler pulley lock bolt and the turn the adjusting bolt to decrease idler pulley tension (Figure 7). Remove the A/C compressor/generator drive belt.
45. Remove both front tire and wheel assemblies.
46. Remove the cotter pin, lock nut and spring washer from the end of both outer C/V joint stub axles (Figure 8).
47. Remove both of the stub axle to hub/bearing retaining nuts (Figure 9).
48. Remove the left front disc brake caliper assembly to steering knuckle guide pin attaching bolts (Figure 10).
49. Remove the left disc brake caliper from the steering knuckle by lifting the bottom away from the knuckle and then removing the top of the caliper out from under the knuckle (Figure 11).
50. Support the caliper assembly with a wire hook. Do NOT let the caliper hang by the brake hose.
51. Remove the brake rotor from the front hub.
52. Remove the outer tie rod end to steering knuckle nut. Remove the nut from the tie rod end by holding the tie rod end stud with an 11/32" socket and then loosening and removing the nut (Figure 12).
53. Separate the tie rod end from the steering knuckle arm using Special Tool MB991113 (Figure 13).
54. Remove the cotter pin and castle nut from the lower ball joint stud at the steering knuckle (Figure 14).
55. Turn the steering knuckle so that the front of the steering knuckle is facing as far outboard as possible.
56. Using a hammer, strike the steering knuckle boss until the steering knuckle separates from the lower ball joint stud (Figure 15).
CAUTION:
Use care to not hit the ball joint grease seal, the lower control arm or the axle shaft.
57. Remove the stub axle to hub/bearing retaining nut and pull the steering knuckle assembly out and away from the outer C/V joint of the driveshaft assembly (Figure 16).
NOTE:
Do not separate the inner C/V joint during this operation. Do not allow the driveshaft to hang by the inner C/V joint. The driveshaft must be supported.
58. Insert a pry bar between the inner tripod joint and the transaxle case (Figure 17). Pry against the inner tripod joint until the tripod joint retaining snap ring is disengaged from the transaxle side gear.
59. Hold the driveshaft by the inner tripod joint and interconnecting shaft. Remove the inner tripod joint from the transaxle by pulling it straight out of the transaxle side gear (Figure 18).
CAUTION:
When removing the tripod joint, do not let the spline or snap ring drag across the sealing lip of the transaxle to tripod joint oil seal.
60. Remove the right front driveshaft by repeating Steps 48 - 59 for that side.
61. Disconnect the exhaust pipe from the rear exhaust manifold.
62. Remove the through bolt from the rear engine mount (Figure 19).
63. Remove the upper attaching bolt from the rear support strut bracket (Figure 19).
64. Remove the bolts that attach the engine support module to the rear crossmember.
65. Disconnect the power steering fluid cooler from the lower radiator support.
66. Remove the bolts that attach the engine support module to the lower radiator support (Figure 19).
67. Remove the lower radiator support.
68. Remove the through bolt from the front engine mount and then remove the engine support module (Figure 19).
69. Remove the rear engine block to transmission support bracket.
70. Remove the power steering pump and reservoir.
71. Remove the A/C compressor.
72. Mount Special Tool Bracket 6973 to the rear right side of the engine block (Figure 20).
73. Position engine dolly and cradle (Special Tools 6135 and 6810) under the vehicle (Figure 21).
74. Loosen the cradle engine mounts to allow for positioning into the locating holes in the special tool bracket and engine bedplate.
75. Lower the vehicle slowly and position the cradle mounts so that the engine is resting on the mounts. Tighten the mounts to the cradle frame.
76. Lower the vehicle so that the weight of the engine and transmission ONLY is on the cradle.
77. Remove the three (3) through bolts from the right engine mount (Figure 22).
78. Remove the three (3) through bolts from the transmission mount (Figure 23).
79. Raise the vehicle slowly about 12-18 inches. It may be necessary to move the engine/transmission assembly on the cradle to clear body flanges.
80. Disconnect the oxygen sensor electrical connector.
81. Remove the power steering line brackets from the rear of the engine.
82. Disconnect the low pressure hose from the power steering reservoir and remove it from the engine bracket.
83. Disconnect the primary ground cable from the left end of the transmission.
84. Continue raising the vehicle slowly. It may be necessary to move the engine/transmission assembly on the cradle to clear body flanges.
85. Continue with Section "C" -- Replace Cylinder Head Core Plugs.