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Engine Assembly Replacement Alternate Method


ENGINE ASSEMBLY REMOVAL AND INSTALLATION (ALTERNATE METHOD)












NOTE: The preferred method of removing the engine assembly is through the bottom of the vehicle. If the necessary equipment is not available, use the alternate service removal procedure.

TOOL REQUIRED
^ J 37088 Fuel Line Quick Connect Separator
^ J 39465 Engine Tilter

REMOVE OR DISCONNECT
1. Disable the Supplemental Inflatable Restraint (SIR) system. Service and Repair
2. Recover the air conditioning system. Service and Repair
3. Air cleaner and intake duct.
4. Drain cooling system.
5. Engine cover.
6. Hood.
7. Cross tower brace.
8. Radiator upper cover.
9. Left and right engine mount struts. Reinstall the bolt in the left front engine mount strut bracket as this will be used as an engine lift point.
10. Upper and lower radiator hoses.
11. Disconnect the forward discriminating sensor from the radiator support and set it aside.
12. Cooling fans.
13. Transaxle cooler lines from the radiator.
14. Radiator upper mounting panel.
15. Disconnect the A/C condenser from the radiator.
16. Radiator.
17. Throttle and cruise control cables from the throttle body.
18. Brake booster vacuum hose from the intake manifold.
19. Using Fuel Line Quick Connect Separator disconnect the fuel inlet and return lines.
20. Coolant reservoir.
21. A/C line between the accumulator and the evaporator.
22. Disconnect the coolant hoses from the pipes at the front of the engine.
23. Accessory drive belt.
24. Negative battery cable from the left cylinder head.

Starter Motor Mounting:






25. Positive battery cable from the battery and the body retainer.
26. Shift cable from the shift lever and the bracket.
27. Park/Neutral switch and bracket.
28. Transaxle vent hose and the shift cable from the throttle body bracket.
29. Throttle Position (TP) Sensor, the Mass Air Flow (MAF) sensor, Knock sensor and Idle Air Control (IAC) valve connector.
30. Ignition coil and the spark plug wires.
31. Throttle body coolant hose at the water cross over.
32. Exhaust Gas Recirculation (EGR) pipe and the crankcase vent pipe from the throttle body.
33. Fuel rail ground wire from the right cylinder head and disconnect the fuel rail bracket from the EGR valve.
34. Positive Crankcase Ventilation (PCV) valve from the right cam tower.
35. Disconnect the injector harness main electrical connector.
36. Intake manifold.
37. Starter. Service and Repair
38. Cylinder head temperature switch electrical connector and ground wire from the right cylinder head.
39. Raise and suitably support the vehicle.






40. Transaxle to oil pan brace.
41. Left transaxle to engine brace.
42. Front engine splash shield and the flywheel inspection cover.
43. Torque converter from the flywheel.
44. Disconnect the A/C compressor, generator, crank sensor, left oxygen sensor, oil level sensor and oil pressure sensor electrical connectors and disconnect the harness from the engine.
45. Right engine splash shield.
46. A/C compressor and set aside. Service and Repair
47. Left motor mount to cradle.
48. Post converter oxygen sensor heat shield.
49. Pre-converter oxygen sensor electrical connector.
50. Intermediate pipe hangers and the catalytic converter from the "Y" pipe.
51. Right front engine to transaxle brace.
52. Transaxle to cylinder head support from the transaxle.
53. Ground wire from the right side of the engine.
54. Power steering pressure line retainer from the front of the engine.
55. Left rear transaxle to engine brace from the transaxle.
56. Lower the vehicle.
57. Left rear transaxle to the engine brace.
58. Disconnect the engine harness from the right cam cover and set it aside.
59. Disconnect the vacuum line connector near the engine harness pass through.
60. Power steering pump pressure and return lines from the pump. Service and Repair
61. Coolant cross over pipe.






62. Four transaxle to engine (bell housing) bolts.
63. Connect an engine lifting fixture to the engine using support hooks at the left rear and the right rear of the engine. Use the torque strut bracket at the left front of the engine for the third lift point. A load tilting device such as Engine Tilter will provide an extra degree of adjustment.
64. Engine from the vehicle.


INSTALL OR CONNECT
1. Lower the engine into position into the chassis. Use caution when moving the engine to prevent damage.





2. Install four engine to transaxle (bell housing) bolts.
Tighten Bolts to 100 Nm (74 ft. lbs.).

3. Lifting fixture from the engine.
4. Coolant cross over pipe.
5. Power steering pump pressure and return the lines to the pump.
6. Vacuum line connection near the engine harness pass through.
7. Engine harness to the right cam tower and the six electrical connections.
8. Left rear transaxle to the engine brace.
9. Raise and suitably support the vehicle.
10. Left rear transaxle to engine brace to the transaxle.
11. Power steering pressure line retainer to the front of the engine.
12. Connect the ground wire to the right side of the engine and bolt attaching the transaxle to the cylinder head brace.
13. Transaxle to cylinder head support to the transaxle.
14. Right front engine to the transaxle brace.
15. Catalytic converter to the exhaust manifold rear pipe.
16. Intermediate pipe hangers.
17. Electrical connection at the pre-converter oxygen sensor and heat shield.
18. Two nuts attaching the left motor mount to the cradle.
19. A/C compressor to the engine.
20. Right engine splash shield.
21. A/C compressor, Generator, Crank Sensor, Oxygen Sensor, Oil Level Sensor, and Oil Pressure Sensor Electrical connectors.
22. Torque converter to the flywheel.
TIGHTEN Torque converter to 47 Nm (35 ft. lbs.).

23. Flywheel inspection cover.
24. Front engine splash shield.





25. Left transaxle to the engine brace.





26. Transaxle to the oil pan brace.
Tighten Bolt to 50 Nm (37 ft. lbs.).

27. Lower the vehicle
28. Ignition coil pack and the spark plug wires.
29. Cylinder head temperature switch electrical connector and ground wire to the rear of the right cylinder head.
30. Starter.
31. Intake manifold.
32. Injector harness main electrical connector.
33. PCV valve to the right cam cover.
34. Fuel rail bracket to the EGR valve.
35. Fuel rail ground wire to the right cylinder head.
36. EGR pipe and the crankcase vent pipe to the throttle body.
37. Throttle body coolant hose at the water crossover.
38. TP Sensor, the MAP Sensor, and the IAC Valve electrical connectors.
39. Transaxle vent hose and shift cable to the throttle body bracket.
40. Park/Neutral switch and bracket.
41. Shift cable to the shift lever and bracket.
42. Positive battery cable to the battery and the body retainer.
43. Negative battery cable to the left cylinder head.
44. Accessory drive belt.
45. Coolant hoses to the pipes at the front of the engine.
46. Coolant reservoir.
47. A/C line between the accumulator and the evacuator core.
48. Fuel lines to the fuel rail.
49. Brake booster vacuum hose to the intake manifold.
50. Throttle and cruise control cables to the throttle body.
51. Radiator.
52. A/C condenser to the radiator.
53. Cooling fans.






54. Transaxle cooler lines.
55. Forward discriminating sensor to the radiator support.
56. Upper and lower radiator hoses.
57. Right and left engine mount struts and adjust to zero preload.
58. Radiator upper cover.
59. Cross tower brace.
60. Hood.
61. Engine top cover.
62. Air cleaner assembly.
63. Air intake duct and the air cleaner.
64. Refill cooling system.
65. Recharge the A/C system.
66. Enable the SIR.
67. Bleed the power steering system.
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