Removal and Replacement
REMOVAL1. Release fuel pressure.
Fig. 41
2. Disconnect negative cable at remote jumper terminal located at right strut tower (Fig. 41).
3. Mark hood position at hinges and remove hood.
4. Drain cooling system.
5. Remove both wiper arms.
Fig. 42
6. Remove right and left cowl covers (Fig. 42).
Fig. 43
7. Remove cowl support (Fig. 43).
Fig. 44
8. Remove air cleaner assembly and air inlet hose (Fig. 44).
9. Remove upper radiator crossmember.
11. Disconnect hood release cable from hood latch.
12. Remove cooling fan module.
13. Disconnect upper radiator hose at engine.
14. Disconnect lower radiator hose at radiator.
15. Disconnect engine oil cooler lines at radiator (if equipped).
16. Disconnect transmission oil cooler lines at radiator.
17. Remove fasteners attaching A/C condenser to radiator.
18. Remove transaxle cooler lines support bracket and attaching screw at left side of radiator.
19. Remove radiator.
20. Remove accessory drive belts.
21. Remove power steering pump mounting bolts and set pump aside.
NOTE: Generator can be removed with engine assembly.
22. Disconnect A/C compressor electrical connector.
23. Remove A/C compressor mounting bolts and set compressor aside.
24. Loosen and remove V-Band clamps at exhaust manifolds.
26. Disconnect throttle and speed control cables.
26. Disconnect coolant hoses at coolant pressure bottle.
27. Disconnect heater hoses.
28. Perform fuel pressure release procedure and disconnect fuel line.
29. Disconnect all vacuum lines and electrical connectors.
30. Disconnect all ground straps attaching to engine.
31. Hoist vehicle and drain engine oil.
32. Remove fasteners supporting catalytic converter down pipes at front and rear mounts.
33. Remove structural collar bolts from oil pan and transaxle. Remove structural collar.
34. Mark flex plate to torque converter position. Remove torque converter bolts.
35. Disconnect both transaxle cooler line brackets from engine.
36. Remove starter.
37. Remove crankshaft position sensor.
38. Remove the two lower transaxle to block bolts.
39. Lower vehicle.
40. Remove EGR valve assembly.
41. Remove screws attaching fuel line and electrical harness to the throttle body bracket.
42. Remove the fasteners attaching the following brackets to the transaxle to block double-ended bolts:
- Electrical harness attaching bracket.
- Transaxle shift cable attaching bracket.
- Throttle body support bracket.
43. Remove the upper transaxle to block bolts.
44. Remove right and left engine mount isolator to engine mount bracket fasteners.
CAUTION: Intake manifolds and cylinder head covers are a composite design. Therefore, care should be taken when lifting the engine from engine compartment.
Fig. 45
45. Attach Special Tool 8342, Engine Lifting Fixture to engine at the locations shown in (Fig. 45).
46. Support transaxle with a floor jack.
47. Hoist engine from engine compartment.
INSTALLATION
1. Attach Special Tool 8342, Engine Lifting Fixture to engine (Fig. 45). Lower engine into engine compartment.
CAUTION: Do not tighten the transaxle case to engine block bolts until all bolts have been hand started, and the two mating surfaces are completely joined together, as damage to cylinder block or transaxle could occur.
2. Align engine mounts and install fasteners but do not tighten until all mounting bolts have been installed.
3. Install transaxle case to engine block bolts and tighten to 102 Nm (75 ft. lbs.).
4. Remove Engine Lifting Fixture.
5. Tighten left and right engine mount isolator to engine mount bracket fasteners to 61 Nm (45 ft. lbs.).
6. Raise vehicle.
7. Align flex plate to torque converter and install mounting bolts tighten to 76 Nm (55 ft. lbs.).
8. Install crankshaft position sensor.
9. Install starter.
10. Install the transaxle oil cooler lines bracket to engine
11. Install structural collar to oil pan and transaxle.
12. Lower vehicle.
13. Install rear throttle body support bracket.
14. Install electrical harness and fuel line support brackets to the throttle body support bracket.
15. Install fastener attaching electrical harness bracket to the transaxle to block bolt.
16. Install EGR valve assembly.
17. Connect heater hoses.
18. Connect all ground straps to engine.
19. Connect all vacuum hoses and electrical connectors.
20. Connect both hoses at coolant pressure bottle.
21. Connect throttle and speed control cables.
22. Connect fuel line.
NOTE: Do not reuse V-Band clamps.
23. Install new V-Band clamps at exhaust manifolds and tighten to 11 Nm (100 in. lbs.).
24. Install catalytic converter down pipe front and rear supports.
25. Install air conditioning compressor and tighten fasteners to 28 Nm (250 in. lbs.)
26. Install power steering pump and tighten fasteners to 28 Nm (250 in. lbs.).
27. Install radiator.
28. Connect engine oil cooler lines to radiator (if equipped).
29. Connect transmission oil cooler lines to radiator.
30. Attach A/C condenser to radiator.
31. Install lower radiator hose.
32. Install upper radiator hose.
33. Install accessory drive belts and cooling fan module.
34. Refill cooling system.
35. Fill engine with proper amount of oil.
36. Connect hood release cable to hood latch and install upper radiator crossmember.
37. Install air cleaner and air inlet hose.
38. Install cowl support.
39. Install right and left cowl covers.
40. Install both wiper arms.
41. Install hood.
42. Connect negative cable to remote jumper terminal at right strut tower.