Engine: Service and Repair

1. On models with airbag,disable airbag system, refer to MAINTENANCE PROCEDURES/AIRBAG ARMING & DISARMING.
2. On all models, disconnect battery ground cable, then remove upper radiator cover.
3. Remove front grille and bumper strip by separating clips.
4. Remove ventilation grille screws and grille from under the bumper.
5. Disconnect wiring harness inside bumper and wires for turn signals and headlights.
6. Remove bumper, then coolant expansion tank cover, drain the cooling system, then remove hoses.
7. Remove windshield washer fluid reservoir, then the power steering pump belt.
8. Remove the power steering pump, with hoses attached.
9. Disconnect thermoswitch, oil pressure switch and warm-up regulator.
10. Remove vacuum hose from warm-up regulator, then the warm-up regulator. Pull the ball socket off from accelerator linkage.
11. Disconnect the engine speed sensor (gray wire), reference mark sensor (black wire) and knock sensor (red wire), from cross panel.
12. Disconnect ignition coil tower wire, then remove distributor cap.
13. Disconnect Hall sending unit by pressing securing clip on connector.
14. Remove air guide plate and fan for injector cooling.
15. Remove engine speed and reference mark sensor mount, then remove left engine mount ground strap from below fan mounting.
16. Loosen hoses and bracket, then remove coolant tube.
17. Disconnect thermo-time switch and temperature sensor.
18. Remove cruise control vacuum line, then disconnect cold start valve and idle stabilizer.
19. Disconnect accelerator linkage ground lead and retainer.
20. Disconnect vacuum line from electronic control unit, then remove cold start valve.
21. Disconnect cruise control linkage and accelerator cable.
22. Disconnect throttle valve switch, then remove air temperature sensor. Cover opening in intake manifold and intercooler.
23. Disconnect thermoswitch from deflection shield on bleeder valve.
24. Remove injectors and air hose from cylinder head.
25. Loosen clamps, remove air duct, then the air cleaner cover.
26. Loosen clamps, remove hose between throttle valve and intercooler, then the idle stabilizer hose from intercooler.
27. Loosen clamps, remove the hose between turbocharger and intercooler, then the intercooler.
28. Remove exhaust pipe from turbocharger, then the heat shield.
29. Disconnect exhaust pipe from corrugated tube, then from transmission mount and muffler.
30. Loosen clamps, then remove cooling air hose from alternator.
31. Remove alternator belt, then the alternator. Tie alternator aside, leaving wires connected.
32. Remove starter, then tie aside, leaving wires connected.
33. Remove oil cooler hoses from oil filter housing, then the A/C compressor belt.
34. Evacuate A/C system.
35. Loosen lower A/C compressor bracket bolts, disconnect A/C magnetic clutch, then remove A/C compressor and bracket.
36. On models with automatic transmissions, remove three bolts from torque converter.
37. On all models, remove lower and upper left engine to transmission bolts.
38. Place engine supports 10-222-A and 3147 into position, being careful not to damage ignition wires.
39. Raise or lower transmission to desired height, then disconnect left and right engine mounts.
40. Remove any remaining engine to transmission connecting bolts.
41. Attach engine sling 2024-A or equivalent and crane. Attach sling on pulley side in second hole in vertical bar, (position 3). On flywheel side, attach sling in fourth hole in vertical bar, (position 8). Positions marked 1 through 4 on bar must be toward pulley side. Holes in hooks are counted upwards from hook.
42. Lift engine slowly, until load is taken off of mounts, then remove left engine mount.
43. Pry engine from transmission, then remove from vehicle.
44. Reverse procedure to install, noting the following:
a. Ensure dowels for centering engine to the transmission are in the engine block.
b. Replace all self-locking nuts.
c. Adjust accelerator cable.
d. Lubricate clutch release bearing and shaft splines with Mos.2 grease.
e. Tighten all nuts and bolts to specifications.