Removal and Replacement
REMOVAL1. Perform fuel pressure release procedure. Remove fuel line to fuel rail.
2. Disconnect and remove battery and tray.
3. Drain cooling system.
4. Discharge air conditioning system, if equipped. Refer to Heating and Air Conditioning for procedure.
5. Disconnect the following: air intake duct at intake manifold, throttle cables, electrical connectors from throttle body and air cleaner housing.
6. Remove air cleaner housing assembly.
7. Remove upper radiator hose and fan module. Refer to Cooling System for procedure. Cooling System
8. Remove lower radiator hose.
9. Disconnect automatic transmission cooler lines and plug, if equipped.
10. Disconnect shift linkage, electrical connectors, and clutch cable, if equipped with manual transaxle.
11. Disconnect engine wiring harness.
12. Disconnect positive cable from Power Distribution Center (PDC) and ground wire from vehicle body.
13. Disconnect ground wire from the vehicle body-to-engine at the right side strut tower.
14. Disconnect heater hoses.
15. Disconnect vacuum hose from brake booster.
16. Disconnect coolant reserve/recovery hose.
17. Remove accessory drive belts.
18. Remove power steering pump and reservoir and set them aside.
19. Hoist vehicle and remove right inner splash shield.
20. Drain engine oil.
21. Remove front wheels.
22. Remove axle shafts.
23. Disconnect exhaust system from manifold.
24. Disconnect the downstream oxygen sensor connector.
25. Remove lower engine torque strut.
26. Remove structural collar.
27. Lower vehicle and remove A/C compressor.
28. Raise vehicle enough to allow engine dolly and cradle, Special Tools 6135 and 6710 to be installed under vehicle.
Fig. 26
29. Loosen engine support posts to allow movement for positioning onto engine locating holes and flange on the engine bedplate. Lower vehicle and position cradle until the engine is resting on support posts (Fig. 26). Tighten mounts to cradle frame. This will keep support posts from moving when removing or installing engine and transmission.
30. Install safety straps around the engine to cradle (Fig. 26). Tighten straps and lock them into position.
WARNING: Safety straps MUST be used.
31. Raise vehicle enough to see if straps are tight enough to hold cradle assembly to engine.
32. Lower vehicle so weight of the engine and transmission ONLY is on the cradle assembly.
33. Remove the upper engine torque strut.
Fig. 24
Fig. 25
34. Remove right and left engine and transaxle mount through bolts (Fig. 24) and (Fig. 25).
35. Raise vehicle slowly until body is approximately 15 cm (6 inch) above normal engine mounting locations.
36. Remove generator, lower bracket, and upper mounting bolt.
37. Continue raising vehicle slowly until engine/ transaxle assembly clears engine compartment. It may be necessary to move the engine/transmission assembly with the cradle to allow for removal around body flanges.
INSTALLATION
1. Position engine and transmission assembly under vehicle and slowly lower the vehicle over the engine/transaxle assembly until vehicle is within 15 cm (6 inch) of engine mounting locations.
2. Install generator, lower bracket, and adjusting bolt.
3. Continue lowering vehicle until engine/transaxle aligns to mounting locations. Install mounting bolts at the right and left engine/transaxle mounts (Fig. 24) and (Fig. 25). Tighten bolts to 118 Nm (87 ft. lbs.).
4. Install upper engine torque strut.
5. Remove safety straps from engine/transaxle assembly. Slowly raise vehicle enough to remove the engine dolly and cradle.
6. Install axle shafts.
7. Install structural collar. Refer to procedure for tightening sequence.
8. Install lower engine torque strut.
9. Connect exhaust system to manifold. Refer to Exhaust System for procedure and torque specifications.
10. Connect the downstream oxygen sensor.
11. Install A/C compressor and hoses. Refer to Heating and Air Conditioning for procedure.
12. Install accessory drive belts.
13. Install inner splash shield.
14. Install wheels and lower vehicle.
15. Install power steering pump and reservoir.
16. Manual Transmission: Connect clutch cable, reverse light electrical connector and shift linkages.
17. Automatic Transmission: Connect shifter, kickdown linkage and cooler lines.
18. Connect fuel line and heater hoses.
19. Install all ground straps. Connect engine wiring harness.
20. Install lower radiator hose, fan module, and upper radiator hose. Refer to Cooling System for procedures. Cooling System
21. Fill cooling system. Refer to Cooling System for filling procedure. Cooling System Filling
22. Install battery tray and battery.
23. Install air cleaner housing assembly and connect intake duct to intake manifold.
24. Connect all throttle body electrical connectors and linkage.
25. Install oil filter. Fill engine crankcase with proper oil to correct level.
26. Perform camshaft and crankshaft timing relearn procedure as follows:
- Connect the DRB scan tool to the data link (diagnostic) connector. This connector is located in the passenger compartment; at the lower edge of instrument panel; near the steering column.
- Turn the ignition switch on and access the "miscellaneous" screen.
- Select "re-learn cam/crank" option and follow directions on DRB screen.
27. Start engine and run until operating temperature is reached.
28. Ensure engine is properly positioned. Refer to Torque Struts for adjustment procedure. Torque Strut
29. Adjust transmission linkage, if necessary.