Removal and Replacement

ENGINE ASSEMBLY

REMOVAL
1. Perform fuel pressure release procedure.
2. Disconnect negative battery cable.
3. Drain cooling system.
4. Discharge A/C system using a suitable refrigerant recovery machine.
5. Remove throttle body air inlet hose and air cleaner housing assembly.
6. Remove upper radiator crossmember.
7. Disconnect upper and lower radiator hoses at radiator.
8. Using a blade or suitable hose cutter, cut transaxle oil cooler lines off flush with fittings. Plug lines and fittings to prevent debris from entering transaxle or cooler circuit. A service splice kit will be installed upon reassembly
9. Disconnect A/C lines at condenser. Remove cooling module assembly (radiator, fan module, and condenser).
10. Disconnect transmission electrical harness connectors (C104 & C105).
11. Disconnect transmission shift cable.
12. Disconnect engine electrical harness from PCM and bulkhead connectors.
13. Raise vehicle on hoist.
14. Remove both front wheels.
15. Remove left and right splash shields.
16. Remove both axle shafts.
17. Drain engine oil.
18. Remove accessory drive belts.
19. Remove power steering pump from bracket. Do not disconnect power steering lines from pump. Reposition pump and support with suitable retaining strap.
20. Disconnect heater return hose from pipe connection at right front frame rail area.
21. Disconnect A/C compressor electrical connectors.
22. Disconnect exhaust pipe from manifold.
23. Remove through bolts from front and rear engine mounts.
24. Remove rear mount bracket from transmission.
25. Remove structural collar and torque reaction bracket.
26. Mark flex plate to torque converter position. Remove torque converter bolts.
27. Lower vehicle.
28. Disconnect positive cable from battery and PDC.
29. Disconnect ground cable from left side transaxle mount bracket.
30. Disconnect throttle and speed control cables.
31. Disconnect coolant recovery container overflow hose.
32. Disconnect heater hose at thermostat housing.
33. Disconnect all ground straps attaching to engine.
34. Disconnect brake booster and vapor purge vacuum hoses.
35. Disconnect fuel line from fuel rail.
36. Disconnect generator connectors.
37. Remove intake manifold.
38. Remove generator.
39. Remove AIR pump (if equipped).
40. Remove A/C suction line at compressor. Cap suction port and line.
41. Remove A/C compressor.

Fig. 6:

42. Raise vehicle enough to allow engine dolly 6135 and cradle 6710 with posts 6848 to be installed under vehicle (Fig. 6).
43. Loosen cradle engine mounts to allow movement for positioning onto engine locating holes on the engine bedplate, compressor and support bracket. Install adapters 6909 to the two post at rear of engine. Lower vehicle and position cradle mounts until the engine is resting on posts. Tighten post mounts to cradle frame. This will keep mounts from moving when removing or installing engine/transmission assembly. Secure engine/transmission to dolly/ cradle with safety straps.
44. Lower vehicle so weight of the engine and transmission ONLY is on the cradle.
45. Remove right and left side vertical engine mount bolts.
46. Slowly raise vehicle in short length spans. Inspect at each interval for potential engine or transaxle contact to vehicle components. Move the cradle/ dolly fixture as necessary to allow for removal clearance.

INSTALLATION
1. Position engine/transaxle assembly under vehicle and slowly lower vehicle in short length spans. Inspect at each interval for potential engine or transaxle contact to vehicle components. Move the cradle/ dolly fixture as necessary to allow for installation clearance.
2. Continue lowering vehicle until right side engine mount and left side transaxle mount align to their mounting locations. Install mounting bolts and torque to 61 Nm (45 ft. lbs.).
3. Remove safety straps from engine/transaxle assembly. Slowly raise vehicle enough to remove the engine dolly and cradle.
4. Install A/C compressor.
5. Connect A/C suction line to compressor.
6. Install AIR pump (if equipped).
7. Install generator.
8. Install intake manifold. Torque fasteners to 12 Nm (105 inch lbs.).
9. Connect generator connectors.
10. Connect fuel line to fuel rail.
11. Connect brake booster and vapor purge hoses.
12. Connect all ground straps to engine.
13. Connect heater hose to thermostat housing.
14. Connect coolant recovery container overflow hose.
15. Connect throttle and speed control cables.
16. Connect ground cable to left side transaxle mount bracket.
17. Connect positive cable to battery and PDC.
18. Raise vehicle on hoist.
19. Install torque converter bolts.
20. Install structural collar and torque reaction bracket.
21. Install rear mount bracket to transmission.
22. Install front and rear engine mount through bolts. Torque fasteners to 61 Nm (45 ft. lbs.).
23. Connect exhaust pipe to exhaust manifold. Torque fasteners to 28 Nm (250 inch lbs.).
24. Connect A/C compressor electrical connectors.
25. Connect heater return hose to pipe connection at right front frame rail area.
26. Install power steering pump to bracket.
27. Install accessory drive belts.
28. Install both axle shafts.
29. Install new oil filter.
30. Install left and right splash shields.
31. Install both front wheels.
32. Lower vehicle.
33. Connect engine electrical harness to PCM and bulkhead connectors.
34. Connect transmission shift cable.
35. Connect transmission electrical connectors (C104 & C105)
36. Install cooling module assembly (radiator, fan module, and condenser). Connect A/C lines to condenser.
37. Connect transmission oil cooler lines using service splice kit. Refer to instructions provided with kit.
38. Connect upper and lower radiator hoses.
39. Install upper radiator crossmember.
40. Install throttle body air inlet hose and air cleaner housing assembly.
41. Fill engine crankcase with proper oil to correct level.
42. Evacuate and recharge A/C system.
43. Fill cooling system.
44. Connect negative battery cable.
45. Start engine and run until normal operating temperature is reached.