Removal and Replacement

Removal Procedure

Tools Required
^ J 37088-A Fuel Line Quick Connect Separator
^ J 39580 Universal Engine Support Table

1. Disable the SIR. Refer to Disabling the SIR System in Restraint Systems.
2. Recover the air-conditioning system. Refer to Refrigerant Recovery and Recharging in Heating and Air Conditioning.





3. Remove the tower-to-tower brace.
4. Remove the air intake duct.
5. Remove the air cleaner assembly.
6. Remove the drain cooling system. Refer to Draining and Filling Cooling System in Cooling System.
7. Remove the radiator hose at the crossover.
8. Remove the engine cover.
9. Remove the radiator upper cover.
10. Remove the upper radiator hoses from the engine.
11. Remove the forward discriminating sensor from the radiator support and set it aside.
12. Remove the cooling fans. Refer to Cooling Fan Replacement - Electric in Cooling System.
13. Remove the transmission cooler lines from the radiator.
14. Remove the cruise control servo connections.
15. Remove the throttle and cruise control cables from the throttle body.
16. Remove the shift cable from the manual shift lever and the bracket.
17. Remove the vacuum hose from the brake booster.
18. Using the J 37088-A disconnect the fuel inlet and return the lines.
19. Remove the coolant reservoir.
20. Remove the coolant hoses from the pipes at the front of the engine.
21. Remove the negative battery cable from the left cylinder head. Refer to Battery Disconnect Caution in Service Precautions.
22. Remove the positive battery cable from the battery and body retainer.
23. Remove the PCM case and the PCM.
24. Remove the right sound insulator.
25. Remove the engine wire harness electrical connector and the vacuum line under the instrument panel.
26. Remove the wire harness from the pass through at the cowl and pull the harness through the cowl.
27. Remove the three electrical connectors from the A/C line near the engine cowl.
28. Remove the vacuum hose from the "T" fitting near the engine harness pass through.
29. Remove the right and left front wheel speed sensor electrical connectors.
30. Remove the MAP sensor and the control motor near the master cylinder.
31. Remove the engine harness retainer from the brake booster.
32. Remove the two hoses from the power steering cooler.
33. Remove the engine harness from the hood fuse panel.
34. Remove the three relays from the lower radiator and the electrical connector from the ABS modulator.
35. Remove both tires and wheels.
36. Separate the drive axles from the steering knuckle. Refer to Wheel Drive Shafts Replacement.
37. Remove the post oxygen sensor heat shield.
38. Remove the post oxygen sensor wire harness connector from the body.
39. Remove the exhaust front pipe. Refer to Front Pipe Replacement in Exhaust System.
40. Remove the steering coupling from the steering gear.
41. Remove the fuel line bundle from the transmission.
42. Remove the battery wire from the generator.
43. Remove the A/C manifold from the A/C compressor. Refer to Compressor Hose Assembly Replacement in Heating and Air Conditioning.
44. Remove the ABS modulator from the frame and support.
45. Position the powertrain support table J 39580 under the frame and lower the vehicle onto the table.
46. Remove the six frame to body bolts.
47. Raise the body off the powertrain.
48. Remove the coolant crossover pipe from the engine.
49. Remove the Park/Neutral switch from the transmission.
50. Remove the engine wire harness.
51. Remove the exhaust "Y" pipe.
52. Remove the accessory drive belt. Refer to Drive Belt Replacement.
53. Remove the power steering pump and hoses. Refer to Power Steering Gear Replacement in Steering and Suspension.
54. Remove the generator and the bracket. Refer to Generator Replacement.
55. Remove the A/C compressor and the bracket. Refer to Compressor Mounting Bracket Replacement in Heating and Air Conditioning.
56. Remove the idler pulley.





57. Remove the right engine to transmission brace.





58. Remove the lower engine to the transmission brace.
59. Remove the left engine to the transmission brace.
60. Attach the engine lift to the engine.
61. Remove the left engine mount and bracket.
62. Remove the left exhaust manifold. Refer to Exhaust Manifold Replacement (Left) or Exhaust Manifold Replacement (Right).
63. Remove the flywheel inspection cover.
64. Remove the torque converter from the flywheel.
65. Remove the right engine mount bracket from the engine.





66. Remove the transmission (bell housing) to engine bolts.
67. Remove the engine from the transmission and frame assembly.
68. Remove the cross under pipe, EGR.
69. Remove the right exhaust manifold. Refer to Exhaust Manifold Replacement (Left) or Exhaust Manifold Replacement (Right).

Installation Procedure
1. Install the right exhaust manifold. Refer to Exhaust Manifold Replacement (Left) or Exhaust Manifold Replacement (Right).





2. Install the cross under pipe, EGR.
3. Install the engine to transmission and frame assembly.

Notice: Refer to Fastener Notice in Service Precautions.

4. Install four transmission (bell housing) to engine bolts.
Tighten the bolts to 75 Nm (55 ft. lbs.).
5. Install the right engine mount bracket to the engine.
6. Install the torque converter to the flywheel.
Tighten the torque converter bolts to 47 Nm (35 ft. lbs.).
7. Install the flywheel inspection cover.
8. Install the left exhaust manifold. Refer to Exhaust Manifold Replacement (Left) or Exhaust Manifold Replacement (Right).
9. Install the left engine mount and bracket.
10. Disconnect the engine lift from the engine.
11. Install the left engine to the transmission brace.





12. Lower the engine to the transmission brace.
13. Install the right side engine to the transmission brace.
14. Install the right side coolant pipes to the engine.
15. Install the power steering lines to the pump and the pump to the engine. Refer to Power Steering Gear Replacement in Steering and Suspensions.
16. Install the idler pulley.
Tighten the bolts to 50 Nm (37 ft. lbs.).
17. Install the A/C compressor and the brackets to the engine. Refer to Compressor Mounting Bracket Replacement in Heating and Air Conditioning.
18. Install the generator and bracket to the engine. Refer to Generator Replacement.
19. Install the power steering pump pulley. Refer to Power Steering Pulley Replacement in Steering and Suspension.
20. Install the drive belt. Refer to Drive Belt Replacement.
21. Install the exhaust manifold rear pipe.
22. Install the engine wire harness.
23. Install the Park/Neutral switch and bracket to the transmission.
24. Install the coolant crossover pipe.
25. Position the powertrain assembly under the body.
26. Lower the body onto the powertrain assembly.
27. Install the frame to body bolts.
Tighten the frame to body bolts to 100 Nm (74 ft. lbs.).
28. Install the ABS modulator to the frame.
29. Install the A/C manifold to the A/C compressor. Refer to Compressor Hose Assembly Replacement in Heating and Air Conditioning.
30. Install the battery wire to the generator.
31. Install the fuel line bundle to the transmission.
32. Install the steering coupling to the steering gear.
33. Install the exhaust front pipe. Refer to Front Pipe Replacement in Exhaust System.
34. Install the intermediate pipe hangers to the intermediate pipe.
35. Install the post converter oxygen sensor electrical connection.
36. Install the post converter oxygen sensor heat shield.
37. Install the drive axle to the hubs. Refer to Wheel Drive Shafts Replacement.
38. Install the tie rods.
39. Install the height sensor links.
40. Install the stabilizer shaft links.
41. Install the tire and the wheels.
Tighten the wheel nuts to 140 Nm (103 ft. lbs.).
42. Lower the vehicle.
43. Install three relays to the radiator support.
44. Install two hoses to the power steering cooler.
45. Install the engine harness to under the hood fuse panel.
46. Install the engine harness retainer to the brake booster.
47. Install the engine harness left front wheel speed sensor, cruise control motor and MAP sensor electrical connector near the master cylinder.
48. Install the right front wheel speed sensor electrical connector.
49. Install the 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 I/P.
53. Install the right sound insulator.
54. Install the 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. Install the coolant hoses to the pipes at the front of the engine.
58. Install the coolant reservoir, hoses and electrical connector.
59. Install the fuel lines to the fuel rail.
60. Install the vacuum hose to the brake booster.
61. Install the shift cable to the manual shift lever and bracket.
62. Install the throttle and cruise cables to the throttle body.
63. Install the cooling fans. Refer to Cooling Fan Replacement - Electric in Cooling System.





64. Connect the transmission cooler lines to the radiator. Install the forward discriminating sensor to the radiator support.
66. Install the upper and lower radiator hoses.
67. Install the engine mount struts and adjust to zero preload. Refer to Engine Mount Strut Replacement.
68. Install the radiator upper cover.
69. Install the engine cover.
70. Install the air cleaner assembly.
71. Install the air intake duct.
72. Fill cooling system. Refer to Draining and Filling Cooling System in Cooling System.
73. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging in Heating and Air Conditioning.
74. Enable the SIR. Refer to Enabling the SIR System in Restraint Systems.
75. Bleed the power steering system. Refer to Bleeding the Power Steering System in Steering and Suspensions.
76. Perform the CKP system variation learn procedure. Refer to CKP System Variation Learn Procedure.