Removal and Replacement
REMOVAL - ENGINE ASSEMBLY1. Perform fuel pressure release procedure
2. Disconnect battery negative cable.
3. Remove air cleaner housing and inlet tube.
4. Disconnect the fuel line from fuel rail.
5. Disconnect all vacuum hoses.
6. Drain cooling system.
7. Remove radiator fans.
8. Remove radiator upper and lower hoses.
NOTE: When the transaxle cooler lines are removed from the rolled-groove type fittings at the transaxle, damage to the inner wall of the hose will occur. To prevent prevent potential leakage, the cooler hoses must be cut off flush at the transaxle fitting, and a service cooler hose splice kit must be installed upon reassembly.
9. Using a blade or suitable hose cutter, cut transaxle oil cooler lines off flush with fittings. Plug cooler lines and fittings to prevent debris from entering transaxle or cooler circuit. A service splice kit will be installed upon reassembly.
10. Disconnect transmission shift linkage and electrical connectors.
11. Disconnect throttle body linkage.
12. Disconnect engine wiring harness.
Fig.5:
13. Disconnect heater hoses from heater (Fig. 5).
14. Discharge air conditioning system.
15. Hoist vehicle and remove front wheels and tires.
16. Remove accessory drive belt splash shield.
17. Remove accessory drive belts.
18. Remove axle shafts.
19. Drain engine oil and remove oil filter.
Fig.6:
20. Remove crossmember cradle plate (Fig. 6).
Fig.7:
21. Disconnect exhaust pipe from manifold (Fig. 7).
22. Remove engine front mount and bracket from engine.
23. Remove structural collar.
24. Remove rear engine mount bracket.
25. Mark flex plate to torque converter and remove torque converter bolts.
26. Pinch-off power steering supply hose at pump. Remove hose from pump.
27. Remove and set aside the power steering pump and bracket. Do not disconnect pressure line.
28. Lower vehicle.
29. Remove A/C lines at compressor and cap openings.
30. Remove engine ground straps (strap at engine right mount and at starter).
Fig.8:
31. Raise vehicle enough to allow engine dolly Special Tool 6135, cradle Special Tool 6710 with Posts Special Tool 6848 to be installed under vehicle (Fig. 8).
32. Loosen cradle posts to allow movement for proper positioning. Locate two rear posts (right side of engine) into the holes on the engine bedplate. Locate the two front posts (left side of engine) on the oil pan rails (Fig. 8). Lower vehicle and position cradle mounts until the engine is resting on mounts. Tighten mounts to cradle frame. This will keep mounts from moving when removing or installing engine and transmission.
33. Install safety straps around the engine to cradle. Tighten straps and lock.
34. Lower vehicle so the weight of ONLY THE ENGINE AND TRANSMISSION are on the cradle.
35. Remove engine and transmission mount bolts.
36. Raise vehicle slowly. It may be necessary to move the engine/transmission assembly with the dolly to allow for removal around the body.
INSTALLATION - ENGINE ASSEMBLY
1. Position engine and transmission assembly under vehicle and slowly lower the vehicle over the engine and transmission.
Fig.9:
Fig.10:
2. Align engine and transmission mounts to attaching points. Install mounting bolts at the right (Fig. 9) and left mounts (Fig. 10).
3. Remove safety straps.
4. Slowly raise vehicle enough to remove the engine dolly and cradle Special Tools 6135 and 6710.
5. Install rear mount bracket and rear mount through bolt.
6. Install the flex plate to torque converter bolts.
7. Install structural collar.
8. Install front mount bracket and front mount through bolt.
Fig.7:
9. Connect exhaust system to manifold (Fig. 7).
10. Install crossmember cradle plate (Fig. 6).
11. Install new oil filter.
12. Install power steering pump and bracket.
13. Connect power steering supply line to pump and remove pinch-off pliers.
14. Connect A/C compressor hoses to compressor.
15. Install accessory drive belts.
16. Install axle shafts.
17. Install accessory drive belt splash shield.
18. Install front wheels and tires.
19. Remove plugs from transmission cooler hoses and install transaxle oil cooler line service splice kit. Refer to instructions included with kit.
20. Connect the transaxle shift linkage and electrical connectors.
21. Connect heater hoses (Fig. 5).
22. Install ground straps.
23. Connect all engine and throttle body electrical connections.
24. Connect all vacuum lines.
25. Connect the throttle cables.
26. Connect the fuel line.
27. Connect radiator lower and upper hoses.
28. Install radiator fans.
29. Fill cooling system.
30. Connect battery cables.
31. Install air cleaner and inlet hose.
32. Fill engine crankcase with proper oil to correct level.
33. Start engine and run until operating temperature is reached.
34. Adjust transmission linkage, if necessary.