Powertrain Assembly Replacement (Preferred Method)

POWERTRAIN ASSEMBLY REMOVAL AND INSTALLATION (PREFERRED METHOD)












TOOL REQUIRED
^ J 37088 Fuel Line Quick Connect Separator
^ J 39580 Universal Engine Support Table

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.

REMOVE OR DISCONNECT
1. Disable the Supplemental Inflatable Restraint (SIR) System. Service and Repair
2. Recover the air-conditioning system. Service and Repair
3. Tower-to-tower brace.
4. Air intake duct.
5. Air cleaner assembly.
6. Drain cooling system.
7. Radiator hose at the crossover.
8. Engine top cover.
9. Radiator upper cover.
10. Upper and lower radiator hoses from the engine.
11. Forward discriminating sensor from the radiator support and set it aside.
12. Cooling fans.
13. Transaxle cooler lines from the radiator.
14. Cruise control servo connections.
15. Throttle and cruise control cables from the throttle body. Service and Repair
16. Shift cable from the manual shift lever and the bracket.
17. Vacuum hose from the brake booster.
18. Using Fuel Line Quick Connect Separator disconnect the fuel inlet and return the lines.
19. Coolant reservoir.
20. Coolant hoses from the pipes at the front of the engine.
21. Negative battery cable from the left cylinder head.

Starter Motor Mounting:

22. Positive battery cable from the battery and body retainer.
23. Powertrain Control Module (PCM) case and the PCM.
24. Right sound insulator.
25. Engine wire harness electrical connector and the vacuum line under the instrument panel.
26. Wire harness from the pass through at the cowl and pull the harness through the cowl.
27. Three electrical connectors from the A/C line near the engine cowl.
28. Vacuum hose from the "T" fitting near the engine harness pass through.
29. Right and left front wheel speed sensor electrical connectors.
30. Manifold Absolute Pressure (MAP) sensor and the control motor near the master cylinder.
31. Engine harness retainer from the brake booster.
32. Two hoses from the power steering cooler.
33. Engine harness from the hood fuse panel.
34. Three relays from the lower radiator and the electrical connector from the Antilock Braking System (ABS) modulator.
35. Both tires and wheels.
36. Separate the drive axles from the steering knuckle. Service and Repair
37. Post oxygen sensor heat shield.
38. Post oxygen sensor wire harness connector from the body.
39. Intermediate pipe hangers form the intermediate pipe.
40. Catalytic converter from the pipe.
41. Steering coupling from the steering gear. Service and Repair
42. Fuel line bundle from the transmission.
43. Battery wire from the generator.
44. A/C manifold from the A/C compressor. Service and Repair
45. ABS modulator from the frame and support.
46. Position the powertrain support table under the frame and lower the vehicle onto the table.
47. Six frame to body bolts.
48. Raise body off powertrain.
49. Coolant crossover pipe from the engine.
50. Park/Neutral switch from the transaxle.
51. Engine wire harness.
52. Exhaust "Y" pipe.
53. Serpentine drive belt.
54. Power steering pump and hoses. Service and Repair
55. Generator and the bracket. Service and Repair
56. A/C compressor and the bracket.
57. Idler pulley.






58. Right engine to transaxle brace.






59. Lower engine to the transaxle brace.
60. Left engine to the transmission brace.
61. Attach engine lift to the engine.
62. Left engine mount and bracket.
63. Left exhaust manifold.
64. Flywheel inspection cover.
65. Torque converter from the flywheel.
66. Right engine mount bracket from the engine.






67. Transaxle (bell housing) to engine bolts.
68. Engine from the transaxle and frame assembly.
69. Cross under pipe, Exhaust Gas Recirculation (EGR).
70. Right exhaust manifold.

INSTALL OR CONNECT
1. Right exhaust manifold.
2. Cross under pipe, EGR.
3. Engine to transaxle and frame assembly.






4. Four transaxle (bell housing) to engine bolts.

TIGHTEN
- Bolts to 75 Nm (55 ft. lbs.).

5. Right engine mount bracket to the engine.
6. Torque converter to the flywheel.

TIGHTEN
- Bolts to 47 Nm (35 ft. lbs.).

7. Flywheel inspection cover.
8. Left exhaust manifold.
9. Left engine mount and bracket.
10. Disconnect the engine lift from the engine.
11. Left engine to the transaxle brace.
12. Lower the engine to the transaxle brace.






13. Right side engine to the transaxle brace.
14. Right side coolant pipes to the engine.
15. Power steering lines to the pump and the pump to the engine.
16. Idler pulley.

TIGHTEN
- Bolts to 50 Nm (37 ft. lbs.).

17. A/C compressor and the brackets to the engine.
18. Generator and bracket to the engine.
19. Power steering pump pulley.
20. Accessory drive belt.
21. Exhaust manifold rear pipe.
22. Engine wire harness.
23. Park/Neutral switch and bracket to the transaxle.
24. Coolant crossover pipe.
25. Position the powertrain assembly under the body.
26. Lower the body onto the powertrain assembly.
27. Frame to body bolts.

TIGHTEN
- Bolts to 100 Nm (74 ft. lbs.).

28. ABS modulator to the frame.
29. A/C manifold to the A/C compressor.
30. Battery wire to the generator.
31. Fuel line bundle to the transaxle.
32. Steering coupling to the steering gear.
33. Catalytic converter to the front pipe.
34. Intermediate pipe hangers to the intermediate pipe.
35. Post converter oxygen sensor electrical connection.
36. Post converter oxygen sensor heat shield.
37. Drive axle to the hubs.
38. Tie rods.
39. Height sensor links.
40. Stabilizer shaft links.
41. Tire and the wheels.

TIGHTEN
- Wheel nuts to 140 Nm (100 ft. lbs.).

42. Lower the vehicle.
43. Three relays to the radiator support.
44. Two hoses to the power steering cooler.
45. Engine harness to under the hood fuse panel.
46. Engine harness retainer to the brake booster.
47. Engine harness left front wheel speed sensor, cruise control motor and MAP sensor electrical connector near the master cylinder.
48. Right front wheel speed sensor electrical connector.
49. Vacuum hose to the "T" fitting near the engine harness pass through.
50. Connect the three electrical connections to the A/C line near the cowl.
51. Push the engine wire harness through the cowl and attach pass through to the cowl.
52. Connect the two engine wire harness electrical connection and vacuum line under the Instrument Panel (I/P).
53. Right sound insulator.
54. PCM case, the PCM and the electrical connection.
55. Connect the positive battery cable to the battery and body retainer.
56. Connect the negative battery cable to the left cylinder head.
57. Coolant hoses to the pipes at the front of the engine.
58. Coolant reservoir, hoses and electrical connector.
59. Fuel lines to the fuel rail.
60. Vacuum hose to the brake booster.
61. Shift cable to the manual shift lever and bracket.
62. Throttle and cruise cables to the throttle body.
63. Cooling fans.






64. Connect the transaxle cooler lines to the radiator.
65. Forward discriminating sensor to the radiator support.
66. Upper and lower radiator hoses.
67. Engine mount struts and adjust to zero preload.
68. Radiator upper cover.
69. Engine cover.
70. Air cleaner assembly.
71. Air intake duct.
72. Fill cooling system. Service and Repair
73. Recharge the A/C system.
74. Enable the SIR.
75. Bleed the power steering system.