Steps 1-42
Engine Replacement^ Tools Required
- J 37097-A Hose Clamp Remover/Installer
- J 38185 Hose Clamp Pliers
- J 39580 Universal Engine Support Table
- J 41623-A Cooler Quick Connect Tool
- J 42504 Engine Lift Bracket
- J 42640 Steering Column Lock Pin
Removal Procedure
1. Disconnect the battery negative cable.
2. Recover the A/C refrigerant system.
3. Disconnect the vacuum brake booster hose from the vacuum connection and position aside.
4. Disconnect the fuel inlet and return quick-connect fittings at the fuel rail and secure to the air inlet grille.
5. Disconnect the hose (4) from the evaporative emission canister purge valve (3) and secure to the air inlet grille.
6. Remove the upper filler panel.
7. Remove the air cleaner assembly.
8. Remove the two nuts (2) from the intake manifold sight shield (1).
9. Remove the sight shield (1) from the engine.
10. Remove the nut (1) securing the battery positive cable to the remote positive terminal and secure to the top of the engine.
11. Disconnect the secondary AIR relay (1) from the relay bracket and secure to the top of the engine.
12. Disconnect and secure the following wiring harness electrical connectors to the top of the engine:
^ The PCM.
^ The C101 (1)
^ The engine electrical harness.
13. Remove the bolt (1) securing the engine ground cable (2) from the right side body frame rail.
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.
14. Push the lock release and remove the cruise control cable (2) from the throttle body bracket and lever (1).
15. Remove the accelerator control cable from the throttle body.
16. Remove the shift cable (2) from the bracket and manual shift lever (1) and position aside.
17. Drain the cooling system.
18. Position the J 37097-A to the clamp in order to remove the radiator inlet hose (1) from the water housing crossover and position aside.
19. Position the J 38185 to the clamp in order to remove the radiator outlet hose (2) from the thermostat housing and position aside.
20. Disconnect the surge tank inlet hose (2) from the surge tank (1).
21. Disconnect the heater hoses (1, 2) from the heater pipes.
Caution: Brake fluid may irritate eyes and skin. In case of contact, take the following actions:
^ Eye contact-rinse thoroughly with water.
^ Skin contact-wash with soap and water.
^ if ingested-consult a physician immediately.
Important: Record the location of the brake pipes to the Brake Pressure Modulator Valve (BPMV) for use as an aid during installation.
22. Remove the two master cylinder brake pipes (1) from the BPMV (2). Plug the open outlet ports to prevent fluid loss and contamination.
23. Remove the upper transaxle oil cooler pipe retaining bolt from the fan shroud.
24. Slide the plastic cap off the upper transaxle oil cooler pipe quick connect fitting.
25. Disconnect the upper transaxle oil cooler pipe from the radiator using the J41623-A.
26. Disconnect the lower transaxle oil cooler pipe fitting from the radiator.
Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly.
27. Lock the steering column by installing the J 42640 into the underside of the steering column.
28. Remove the right and left side strut tower bolts.
29. Raise and support the vehicle. Refer to Vehicle Lifting.
30. Remove the rear exhaust manifold pipe.
31. Remove the front wheels.
32. Disconnect the front wheel speed sensor electrical leads (2) from the body frame rail.
33. Disconnect the road sensing suspension electrical connector at the body frame rail (if equipped).
34. Disconnect the road sensing suspension electrical leads (1) from the body frame rail (if equipped).
35. Disconnect the electronic suspension position sensor links (1) from the lower control arms (if equipped).
36. Remove the front air deflector.
37. Remove the front fascia extensions.
38. Disconnect the secondary AIR inlet hose from the secondary AIR pump.
39. Loosen the nuts (2) securing the front brake pipe frame brackets (1) to the body frame rails.
40. Disconnect the front brake pipes from the retainers at the body frame rails.
41. Carefully pull the front brake pipes away from the body frame rails.
42. Disconnect the two rear brake pipes at the rear of the engine frame.
Plug the open outlet ports to prevent fluid loss and contamination.