Engine Replacement
REMOVAL PROCEDURENotice: Refer to Engine Emission Notice in Service Precautions.
1. Disconnect the battery ground (negative) cable.
2. Drain the engine oil.
3. Drain the engine coolant from the cooling system.
4. Remove the hood.
5. Remove the fuel injector sight shield.
6. Carefully remove the throttle body air inlet duct and the air filter assembly.
7. Remove the inlet radiator hose from the engine.
8. Remove the outlet radiator hose from the engine.
9. Disconnect the A/C compressor from the engine. Secure the compressor to the frame.
10. Disconnect the starter motor wiring harness.
Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle. In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.
11. Disconnect the throttle and cruise cables from the linkage.
12. Remove the wiring harness from the top of the engine.
Important: Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure in Powertrain Management.
13. Disconnect the fuel lines (1, 2) from the fuel rail. Lay the fuel lines aside. Quick Connect Fitting(s) Service (Metal Collar) or Quick Connect Fitting(s) Service (Plastic Collar) in Powertrain Management - 3,8L.
14. Disconnect the fuel vapor line.
15. Disconnect the vacuum booster hose from the engine.
16. Disconnect the A/C vacuum hose from the engine.
17. Disconnect the heater hoses from the engine.
18. Remove the engine mount struts from the engine mount strut brackets.
19. Disconnect the power steering pump from the engine. Lay the power steering pump aside.
20. Raise and suitably support the vehicle.
21. Remove the torque converter cover.
22. Remove the starter motor.
23. Remove the engine flywheel-to-torque converter bolts.
24. Remove the engine mount-to-frame nuts.
25. Remove the transaxle brace.
26. Remove the three-way catalytic converter pipe from the right (rear) exhaust manifold.
27. Remove the lower transmission-to-engine bolts (1, 6).
28. Lower the vehicle.
29. Install the engine lifting device.
30. Remove the upper transmission-to-engine bolts (2 - 5).
31. Remove the engine from the vehicle.
32. Remove the flywheel.
33. Install the engine to the engine stand.
34. Remove the generator.
35. Remove the ignition control module.
36. Remove the drive belt tensioner.
37. Remove the engine mount bracket.
INSTALLATION PROCEDURE
Notice: Refer to Engine Emission Notice in Service Precautions.
1. Install the engine mount bracket.
2. Install the drive belt tensioner.
3. Install the ignition control module.
4. Install the generator.
5. Install the flywheel.
6. Install the engine to the vehicle.
Notice: Refer to Fastener Notice in Service Precautions.
7. Install the upper transmission-to-engine bolts (2 - 5).
^ Tighten the upper transmission-to-engine bolts to 75 Nm (55 ft. lbs.).
8. Remove the engine lifting device.
9. Raise and suitably support the vehicle.
10. Install the lower transmission-to-engine bolts (1, 6).
^ Tighten the upper transmission-to-engine bolts to 75 Nm (55 ft. lbs.).
11. Install the three-way catalytic converter pipe to the right (rear) exhaust manifold.
12. Install the transaxle brace.
13. Install the engine mount to frame nuts.
14. Install the engine flywheel-to-torque converter bolts.
15. Install the starter Motor.
16. Install the torque converter cover.
17. Lower the vehicle.
18. Install the power steering pump to the engine.
19. Install the engine mount struts to the engine mount strut brackets.
20. Connect the heater hoses to the engine.
21. Connect the A/C vacuum hose to the engine.
22. Connect the vacuum booster hose to the engine.
23. Connect the fuel vapor line.
24. Connect the fuel lines (1, 2) to the fuel rail.
25. Install the wiring harness connections to the engine.
Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle. In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.
26. Connect the throttle and cruise cables.
27. Install the starter motor wiring harness.
28. Install the A/C compressor to the engine.
29. Install the outlet radiator hose to the engine.
30. Install the inlet radiator hose to the engine.
31. Carefully install the throttle body air inlet duct and the air filter assembly.
32. Install the hood.
33. Connect the battery ground (negative) cable.
34. Install a new oil filter and fill the engine with new engine oil.
35. Fill the cooling system with engine coolant. Bleed the cooling system.
36. Install the fuel injector sight shield.
37. Inspect all of the fluid levels.
38. Inspect for leaks.