Removal and Replacement
REMOVAL - ENGINE ASSEMBLY1. 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).
5. Disconnect the following:
a) Air intake duct at intake manifold
b) Throttle cables
c) Electrical connectors from throttle body
6. Remove air cleaner housing assembly.
7. Remove radiator upper hose.
8. Remove radiator fan.
9. Remove radiator lower hose.
10. Automatic Transmission equipped vehicles:
a) Using a blade or suitable hose cutter, cut transaxle oil cooler lines off flush with transmission fittings. Plug lines and fittings to prevent debris from entering transaxle or cooler circuit. A service splice kit will be installed upon reassembly.
b) Disconnect transmission electrical connectors.
c) Disconnect transmission shift linkage.
11. Manual Transmission equipped vehicles:
a) Using Special Tool 6638A, disconnect clutch hydraulic line.
b) Disconnect transmission shift linkage.
c) Disconnect transmission electrical connectors.
12. Disconnect engine wiring harness.
13. Disconnect and remove Powertrain Control Module (PCM).
14. Disconnect positive cable from Power Distribution Center (PDC) and ground wire from vehicle body.
15. Disconnect the body-to-engine ground wire at the right side strut tower.
16. Disconnect heater hoses.
17. Disconnect vacuum hose from brake booster.
18. Disconnect coolant reserve/recovery hose.
19. Remove power steering pump drive belt.
20. Siphon as much fluid as possible from the power steering fluid reservoir.
21. Disconnect power steering lines from power steering pump. Remove the power steering pump/reservoir.
22. Disconnect lines and remove air conditioning compressor (if equipped).
23. Hoist vehicle.
24. Remove front wheels.
25. Remove accessory drive belt splash shield.
26. Remove generator drive belt.
27. Drain engine oil.
28. Remove axle shafts.
29. Remove screws attaching power steering cooler (if equipped) and relocate cooler to provide engine removal clearance.
30. Disconnect downstream oxygen sensor connector.
31. Disconnect exhaust system from exhaust manifold.
32. Disconnect exhaust system isolators and move exhaust rearward.
33. Remove lower engine torque strut.
34. Remove generator, lower bracket, and upper mounting bolt.
35. Remove structural collar, intake support bracket, and dust cover (Fig. 6).
36. Automatic Transmission equipped vehicles:
a) Remove torque converter bolts and mark converter to flex plate orientation for reassembly.
37. Manual Transmission equipped vehicles:
a) Remove drive plate to clutch module bolts.
38. Remove bolt securing power steering line to engine block. Reposition power steering line to allow for engine removal.
39. Lower vehicle.
40. Raise vehicle enough to allow engine dolly and cradle, Special Tools 6135 and 6710 to be installed under vehicle.
41. 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. 9). Tighten mounts to cradle frame. This will keep support posts from moving when removing or installing engine and transmission.
42. Install safety straps around the engine to cradle (Fig. 9). Tighten straps and lock them into position.
WARNING: Safety straps MUST be used to secure engine to the dolly fixture.
43. Raise vehicle enough to see if straps are tight enough to hold cradle assembly to engine.
44. Lower vehicle so weight of the engine and transmission ONLY is on the cradle assembly.
45. Remove upper engine torque strut.
46. Remove right and left engine and transaxle mount through bolts (Fig. 7) and (Fig. 8).
47. 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 - ENGINE ASSEMBLY
1. Position engine and transmission assembly under vehicle and slowly lower the vehicle over the engine/transaxle assembly.
2. Continue lowering vehicle until engine/transaxle aligns to mounting locations. Install mounting bolts at the right and left engine/transaxle mounts (Fig. 7) and (Fig. 8). Tighten bolts to 118 Nm (87 ft. lbs.).
3. Install upper engine torque strut.
4. Remove safety straps from engine/transaxle assembly. Slowly raise vehicle enough to remove the engine dolly and cradle.
5. Raise vehicle on hoist.
6. Install generator, lower bracket, and adjusting bolt.
7. Install axle shafts.
8. Automatic Transmission equipped vehicles:
a) Install torque converter bolts.
9. Manual Transmission equipped vehicles:
a) Install drive plate to clutch module bolts.
10. Install bolt securing power steering line to engine block.
11. Install screws for power steering cooler (if equipped).
12. Install dust shield, intake manifold support bracket, and structural collar (Fig. 6).
13. Install lower engine torque strut.
14. Connect exhaust system isolators and catalytic converter to exhaust manifold. Torque exhaust fasteners to 28 Nm (250 inch lbs.).
15. Connect downstream oxygen sensor.
16. Install A/C compressor and lines.
17. Install accessory drive belts.
18. Ensure oil pan drain plug is tight. Install new oil filter.
19. Install accessory drive belt splash shield.
20. Install front wheels and lower vehicle.
21. Install power steering pump and reservoir. Connect power steering lines.
22. Manual Transmission equipped vehicles:
a) Connect clutch hydraulic line.
b) Connect transmission shift linkage.
c) Connect transmission electrical connectors.
NOTE: It is not necessary to bleed the clutch hydraulic system. The quick-connect fittings close immediately after disconnection; allowing no fluid to escape.
23. Automatic Transmission equipped vehicles:
a) Connect transmission oil cooler lines using service splice kit. Refer to instructions provided with kit.
b) Connect transmission electrical connectors.
c) Connect transmission shift linkage.
24. Connect fuel line.
25. Connect heater hoses.
26. Connect all ground straps.
27. Install and connect Powertrain Control Module (PCM).
28. Connect engine wiring harness.
29. Connect lower radiator hose.
30. Install radiator fan.
31. Install upper radiator hose.
32. Fill cooling system.
33. Install battery tray and battery.
34. Install air cleaner housing assembly and connect intake duct to intake manifold.
35. Connect all throttle body electrical connectors and linkage.
36. Fill engine crankcase with proper oil to correct level.
37. Fill power steering fluid reservoir with proper fluid to correct level.
38. Evacuate and recharge Air Conditioning system (if equipped).
39. Start engine and run until operating temperature is reached.
40. Ensure engine is properly positioned by performing torque strut adjustment.
41. Adjust transmission linkage, if necessary.