Removal and Installation

REMOVAL
1. Remove water pump pulley shield bolts from lefthand valve cover, then shield.
2. Disconnect battery cables and wiring from battery.
3. Remove pinch bolt, then disconnect steering shaft and joint in vehicle.
4. Remove air cleaner as follows:
a. Loosen engine air cleaner tube clamps on outlet tube, then disconnect Crankcase ventilation hoses and Idle Air Control (IAC) valve tube from air cleaner outlet tube fitting.
b. Remove air cleaner outlet tube from Mass Air Flow (MAF) sensor and throttle body.
c. Disconnect engine control sensor wiring connector from the MAF and Intake Air Temperature (IAT) sensor.
d. Remove engine air cleaner to body O-ring retainer, then air cleaner body and intake tube from bracket.
e. Remove engine air cleaner intake tube and duct.
5. On models equipped with air conditioning, recover air conditioning system.
6. Raise and support vehicle.
7. Remove three way catalytic converter and Y pipe as follows:

WARNING: Exhaust system normal operating temperature is very high. Never work around or attempt to service any or part of system until it has cooled. Use special care when working around three way catalytic converters. These units heat to a high temperature in only a short period of engine operation.

a. Remove converter outlet flange nuts, then muffler and converter outlet gasket from converter.
b. Remove converter nuts and exhaust pipe flange hold down springs.
c. Remove converter and inlet gasket from Y pipe, then discard gasket.
d. Remove front and rear Y pipe flange fasteners from exhaust manifolds.
e. Remove stud bolt and nut retainer from oil pan, then Y pipe.
8. Drain engine cooling system.
9. Remove front wheel and tire assemblies.
10. Remove stabilizer bar link cotter pins and nuts.
11. Separate stabilizer bar links from front stabilizer bar.
12. Remove front suspension lower arm pinch bolts, then separate front suspension lower arms from front wheel knuckles at ball joint.
13. Remove tie rod end cotter pins and nuts, then separate tie rod ends from front wheel knuckles with tie rod end remover 3290-D, or equivalent.
14. Remove axle wheel hub retainer from halfshaft ends, then halfshafts.
15. Remove A/C accumulator screws from front subframe.
16. Disconnect speedometer drive cable from vehicle speed sensor on transaxle, then sensor wiring harness at connector.
17. If separating engine from automatic transaxle, proceed as follows:
a. Remove engine rear plate access plug, then remove converter retaining nuts.
b. Push torque converter into transaxle front pump support and gear.

Fig. 3 Radiator secured to radiator support:

18. Lower vehicle, then secure radiator and engine cooling fan motor, fan blade and fan shroud assembly to radiator support with safety wire.
19. Disconnect accelerator cable and speed control actuator from throttle body.
20. Remove accelerator cable bracket from throttle body.
21. Remove three engine control sensor wiring connectors from bracket on lefthand front fender apron, then disconnect wiring at connectors.
22. Remove engine control sensor wiring retainer from air cleaner bracket.
23. Disconnect ignition control module electrical connector by carefully lifting up on connector finger ends while grasping connector body and pulling it away from module.
24. Remove ignition module screws, then module from bracket.
25. Remove ignition control module bracket.
26. Remove power steering pump auxiliary reservoir from bracket and position over engine assembly.
27. Disconnect return hose from reservoir. Plug hose end.
28. Disconnect power steering pressure hose from power steering pump.

CAUTION: Do not allow power steering fluid to contact drive belt. Damage to drive belt may occur.

29. Disconnect engine control sensor wiring from Powertrain Control Module (PCM) and retainer on righthand side of dash panel.
30. Remove engine control sensor wiring ground strap from righthand front fender apron.
31. Disconnect coolant hoses from radiator coolant recovery reservoir, then fuel and supply lines from fuel injection supply manifold.
32. On models equipped with automatic transaxle, pry shift cable from stud, then remove shift cable bracket screws, bracket and cable.
33. Disconnect ground strap from transaxle case.
34. Remove vacuum supply line from power brake booster, then upper radiator hose from radiator.
35. Disconnect positive battery cable retainer from battery tray.
36. On models equipped with manual transaxle, remove clutch hydraulic retainer, then disconnect line from clutch actuator pipe at transaxle case.
37. On models equipped with block heater, disconnect block heater power supply wiring from righthand side of radiator support.
38. Raise and support vehicle, then disconnect heater water hoses from heater core.
39. On models equipped with air conditioning, disconnect A/C suction hose from A/C condenser core, then A/C discharge hose from A/C accumulator.
40. On models equipped with manual transaxle, proceed as follows:
a. Remove gearshift lever knob by grasping firmly with both hands and pulling up.
b. Unsnap console applique from console assembly and remove gearshift lever boot.
c. Remove gearshift stabilizer bar to case cover bolts, then raise and support vehicle.
d. Remove middle under body heat shield nuts, then shield.
e. Remove transaxle gear shift rod and clevis from transaxle, then stabilizer bar to bracket nut at righthand transaxle support insulator.
f. Remove gearshift stabilizer bar from vehicle.
41. On models equipped with automatic transaxle, remove transaxle oil cooler lines from transaxle, then return line from bracket on lefthand side of transaxle.
42. Disconnect lower radiator hose from radiator.
43. Remove lower radiator support to front subframe bolts, then rotate radiator supports forward.
44. On models equipped with air conditioning, disconnect A/C compressor wire harness at connectors.
45. Remove two bumper cover brace to lefthand and righthand side of front subframe screws. Rotate bumper cover braces forward.
46. Partially lower vehicle, then position and secure any hoses, lines and components to be removed with engine.
47. Install powertrain and subframe support bracket 134-00250, or equivalent, to Rotunda powertrain lift 134-00251, or equivalent, then rotate transaxle adapters for transaxle removal. Position bracket tool and adjust lift tool to provide proper contact at powertrain lift points.
48. Remove four subframe bolts. Ensure engine is properly positioned and secure on lifting equipment. Damage to vehicle or personal injury may occur if engine is not secure.
49. Remove upper front engine support bracket and engine and transaxle support insulator.
50. With assistance, lower engine and transaxle with front subframe as an assembly. Check for interference to body while lowering powertrain.
51. When powertrain is clear of body, raise and support vehicle.
52. Support engine with Rotunda floor crane positioning sling 014-00036 and Rotunda floor crane 014-00071, or equivalents, from engine lifting eyes.
53. Remove halfshafts from transaxle.
54. Remove front engine support insulators from subframe and transaxle.
55. Raise engine and transaxle assembly and remove front subframe and lift tool, then support transaxle with Rotunda transmission jack 066-00016, or equivalent.
56. Remove starter motor bolts, then starter motor.
57. Disconnect engine control sensor wiring from transaxle at connectors, then remove engine control sensor wiring to transaxle case clips and position engine control sensor wiring aside.
58. Remove battery ground cable from engine to transaxle retaining stud bolt.
59. Remove transaxle to engine bolts and separate transaxle from engine.
60. On models equipped with manual transaxle, remove clutch pressure plate bolts, then pressure plate and clutch disc.
61. Remove the flywheel bolts, then flywheel from crankshaft.
62. Remove engine rear plate, then install engine onto suitable engine stand, following manufacturer's instructions.

INSTALLATION
1. Remove engine from engine stand using Rotunda Floor Crane Positioning Sling 014-00036 and Rotunda floor crane 014-0.0071, or equivalent, attached to engine lifting eyes.
2. Install engine rear plate and flywheel.
3. On models equipped with manual transaxle, install transaxle to engine.
4. On models equipped with automatic transaxle, align torque converter and flywheel, then install transaxle to engine.
5. Place front subframe on powertrain and subframe support bracket 134-00250, or equivalent, then install engine and transaxle assembly onto front subframe with bracket tool.
6. Install powertrain alignment gauge T94P-2100-AH, or equivalent, to lefthand front engine support bracket and front subframe. Torque vertical bolts and through bolt to 20 ft lb.
7. Install battery ground cable to transaxle case.
8. Route engine control sensor wiring across transaxle and install clips for engine control sensor wiring onto transaxle.
9. Connect engine control sensor wiring to transaxle at all connectors.
10. Install starter motor.
11. Install halfshafts into transaxle.
12. Partially lower vehicle, then install engine and transaxle assembly into vehicle with front subframe, using powertrain and subframe support bracket 134-00250 and Rotunda powertrain lift tool 134-00251, or equivalent, with subframe alignment pin set T94P-2100-AH, or equivalent, installed onto front subframe. Ensure engine and transaxle are firmly seated against front and rear insulator brackets.
13. Using new nuts, install upper front engine support bracket and engine and transaxle support insulator.
14. Install front subframe to body, then remove alignment set tool, powertrain lift tool and support bracket tool.
15. Lower vehicle, then tighten front engine support bracket nuts.
16. Tighten engine and transaxle support insulator nuts, then raise and support vehicle.
17. Torque righthand front engine support insulator to subframe bolt to 7 ft lb. Ensure righthand front engine support insulator is centered in bracket and in perfect front-to-rear alignment. Torque insulator to subframe bolt to 30-40 ft. lb.
18. Install lefthand front engine support insulator through bolt.
19. On models equipped with air conditioning, connect wire harness to A/C compressor.
20. Install front bumper cover braces to lefthand and righthand side of front subframe.
21. Install radiator supports to front subframe.
22. Connect lower radiator hose to radiator.
23. On models equipped with automatic transaxle, install transaxle oil cooler lines and brackets.
24. On models equipped with manual transaxle, install shift rod and stabilizer bar to transaxle.
25. On models equipped with air conditioning, connect A/C suction hose to A/C condenser core, then discharge hose to A/C accumulator.
26. Install heater water hoses to heater core, installing hose spring clamp securely
27. Lower vehicle.
28. On models equipped with block heater, connect block heater power supply wiring to righthand side of radiator support.
29. On models equipped with manual transaxle, proceed as follows:
a. Connect clutch hydraulic line to clutch actuator, then install retainer clip.
b. Fill and bleed clutch hydraulic system.
30. Connect positive battery cable retainer to battery tray.
31. Connect upper radiator hose to radiator, then vacuum supply line to power brake booster.
32. Connect ground strap to transaxle case.
33. On models equipped with automatic transaxle, install shift cable and bracket to transaxle.
34. Connect fuel supply and return lines to fuel injection supply manifold, then coolant hoses to radiator coolant recovery reservoir.
35. Install ground strap for engine control sensor wiring to righthand cylinder head.
36. Connect engine control sensor wiring to Powertrain Control Module (PCM), then position engine control sensor wiring into retainer bracket on righthand side of dash panel.
37. Connect power steering pressure hose to power steering pump, then install power steering pressure hose bracket to upper front engine support bracket.
38. Install power steering pump auxiliary reservoir to bracket.
39. Install ignition control module bracket, then module and screws.
40. Connect ignition control module electrical connector.
41. Install engine control sensor wiring to air cleaner bracket retainer. Connect three engine control sensor wiring connectors together, then to bracket located on lefthand front fender apron.
42. Install accelerator cable bracket to throttle body, then connect cables to throttle body lever.
43. Remove safety wire holding radiator to radiator support, then raise and support vehicle.
44. On models equipped with automatic transaxle, push torque converter into flywheel pilot and install torque converter to flywheel nuts. Install access plug onto engine rear plate.
45. Connect speedometer drive cable to vehicle speed sensor, then the speed sensor wiring harness at connector.
46. On models equipped with air conditioning, install A/C accumulator screws to front of subframe.
47. Install halfshafts into front wheel knuckles, then front axle wheel hub retainers.
48. Install tie rod ends to front wheel knuckle. Install new nuts on tie rod end studs. Torque nuts to 21 ft lb and continue tightening nuts to align next castellation of new nut with cotter pin hole in stud. Install new cotter pins.
49. Install front wheel knuckles onto front suspension lower arms at ball joint.
50. Install front wheel and tire assemblies.
51. Install Y pipe and three way catalytic converter as follows:
a. Install Y pipe, then nut retainer and stud bolt to oil pan.
b. Install front and rear Y pipe flange fasteners to exhaust manifolds.
c. Install new converter and inlet gasket to Y pipe.
d. Install exhaust pipe flange hold down springs and converter nuts.
e. Install muffler and converter outlet gasket to converter, then converter outlet flange nuts.
52. Install splash shield to front of subframe and body.
53. Rotate front bumper cover braces rearward, then install two screws to front subframe.
54. Lower vehicle, then install engine air cleaner as follows:
a. Install engine air cleaner intake tube and duct.
b. Install air cleaner body and intake tube to bracket, then air cleaner to body O-ring retainer.
c. Connect engine control sensor wiring connector to Mass Air Flow (MAF) and Intake Air Temperature (IAT) sensors.
c. Install air cleaner outlet tube to MAF sensor and throttle body.
d. Connect crankcase ventilation hoses and IAC valve tube to air cleaner outlet tube fitting.
e. Connect steering shaft and joint in vehicle and install pinch bolt.
55. Install water pump pulley shield, then bolts to lefthand cylinder head.
56. Connect battery cables and wiring to battery, then fill engine cooling system with specified coolant.
57. On models equipped with air conditioning, recharge A/C system.
58. Run engine and check for oil, coolant or fuel leaks, then verify proper cooling fan motor and A/C system operation.