Removal and Replacement

REMOVAL - ENGINE ASSEMBLY
1. Perform fuel pressure release procedure, then disconnect and remove fuel line.
2. Remove air cleaner housing assembly and clean air hose.
3. Disconnect both cables from battery.
4. Remove battery and battery tray.
5. Drain cooling system.
6. Discharge air conditioning system, if equipped.
7. Disconnect throttle and speed control cables from throttle body
8. Disconnect engine wiring harness at Powertrain Control Module (PCM).





9. Disconnect positive cable from Power Distribution Center (PDC) and ground wire from vehicle body Remove bolts attaching PDC and set aside (Fig. 5).
10. Disconnect wiring connectors at lower battery tray support.
11. Disconnect ground wire from the vehicle body-to-engine at the right side strut tower.
12. Disconnect brake booster vacuum hose from intake manifold.
13. Disconnect the proportional purge hose from throttle body
14. Disconnect coolant reserve/recovery hose from coolant outlet connector.
15. Disconnect heater hoses.
16. Remove grill.





17. Remove upper radiator closure and center brace (Fig. 6).
18. Remove upper radiator hose.
19. Remove lower radiator hose.
20. Remove thermostat housing.
21. Disconnect upper A/C line from A/C condenser.
22. Disconnect A/C lines at junction near upper torque strut.
23. Automatic Transmission equipped vehicles:
a. Using a blade or suitable hose cutter, cut transaxle oil cooler lines off flush with transmission fittings. Plug lines and fittings to prevent debris from entering transaxle or cooler circuit. A service splice kit will be installed upon reassembly
b. Disconnect transmission electrical connectors.
c. Disconnect transmission shift linkage.
24. Manual Transmission equipped vehicles:








a. Using Special Tool 6638A, disconnect clutch hydraulic line (Fig. 7) and (Fig. 8).
b. Disconnect transmission shift linkage.
c. Disconnect transmission electrical connectors.
25. Turbocharger equipped vehicles: Disconnect power steering hoses from radiator.
26. Disconnect radiator fan electrical connector and remove cooling module assembly (fan, radiator, A/C condenser, transmission oil cooler).
27. Hoist vehicle and remove front wheels.
28. Remove right and left inner splash shields.
29. Remove both axle shafts.
30. Remove accessory drive belts.
31. Remove generator and support brackets.





32. Turbocharger equipped vehicles: Remove charge air cooler hoses (Fig. 9).
33. Drain engine oil.
34. Disconnect the downstream oxygen sensor connector.








35. Disconnect exhaust system from manifold (Fig. 10) or (Fig. 11).





36. Non-Turbo equipped vehicles: Disconnect power steering pressure hose from steering gear (Fig. 12).





37. Turbocharger equipped vehicles: Disconnect both power steering hoses from steering gear (Fig. 13).





38. Turbocharger equipped vehicles: Remove upper and lower heat shields, elbow support bracket, turbocharger support bracket, and elbow (Fig. 14).
39. Remove structural collar. Engine Mount
40. Automatic Transmission equipped vehicles:
a. Remove torque converter bolts and mark converter to flex plate orientation for reassembly.
41. Manual Transmission equipped vehicles:
a. Remove drive plate to clutch module bolts.
42. Remove lower engine torque strut.
43. Lower vehicle and remove A/C compressor.
44. Disconnect power steering lines from power steering pump.
45. Remove power steering pump.
46. Raise vehicle enough to allow engine dolly, cradle, and posts, (Special Tools 6135, 6710, and 6848) to be installed under vehicle.





47. Loosen engine support posts to allow movement for positioning onto engine locating holes and flange on the engine bedplate. Lower vehicle and position cradle until the engine is resting on support posts (Fig. 17). Tighten mounts to cradle frame. This will keep support posts from moving when removing or installing engine and transmission.
48. Install safety straps around the engine to cradle (Fig. 17). Tighten straps and lock them into position.

WARNING: Safety straps MUST be used.

49. Raise vehicle enough to determine if straps are secure enough to hold cradle assembly to engine.
50. Lower vehicle so weight of the engine and transmission ONLY is on the cradle assembly.
51. Remove the upper engine torque strut.








52. Remove right mount through bolt (Fig. 15) and left mount attaching bolts (Fig. 16).
53. Raise vehicle slowly until engine/transaxle assembly clears engine compartment. It may be necessary to move the engine/transmission assembly with the cradle to allow for removal around body flanges.

INSTALLATION - ENGINE ASSEMBLY
1. Position engine and transmission assembly under vehicle and slowly lower the vehicle over the engine/transaxle assembly.
2. Continue lowering vehicle until engine/transaxle aligns to mounting locations. Install mounting bolts at the right and left engine/transaxle mounts (Fig. 15) and (Fig. 16). Tighten bolts to 118 Nm (87 ft. lbs.).
3. Install upper engine torque strut.
4. Remove safety straps from engine/transaxle assembly. Slowly raise vehicle enough to remove the engine dolly and cradle.
5. Install power steering pump.
6. Connect power steering lines to power steering pump.
7. Install A/C compressor.
8. Install lower engine torque strut.
9. Automatic Transmission equipped vehicles:
a. Install torque converter bolts.
10. Manual Transmission equipped vehicles:
a. Install drive plate to clutch module bolts.
11. Install structural collar.
12. Turbocharger equipped vehicles: Install elbow, turbocharger support bracket, elbow support bracket, and upper and lower heat shields (Fig. 14).
13. Non-Turbo equipped vehicles: Connect power steering pressure hose to steering gear (Fig. 12).
14. Turbocharger equipped vehicles: Connect both power steering hoses to steering gear (Fig. 13).
15. Connect exhaust system to manifold (Fig. 10) or (Fig. 11).
16. Connect the downstream oxygen sensor.
17. Turbocharger equipped vehicles: Install charge air cooler hoses (Fig. 9).
18. Install generator and mounting brackets.
19. Install accessory drive belts.
20. Install axle shafts.
21. Install right inner splash shield.
22. Install wheels and lower vehicle.
23. Install cooling module assembly (fan, radiator, A/C condenser, transmission oil cooler). Connect radiator fan electrical connector.
24. Turbocharger equipped vehicles: Connect power steering hoses to radiator.
25. Manual Transmission equipped vehicles:
a. Connect clutch hydraulic line (Fig. 7).
b. Connect transmission shift linkage.
c. Connect transmission electrical connectors.

NOTE: It is not necessary to bleed the clutch hydraulic system. The quick-connect fittings close immediately after disconnection; allowing no fluid to escape.

26. Automatic Transmission equipped vehicles:
a. Connect transmission oil cooler lines using service splice kit. Refer to instructions provided with kit.
b. Connect transmission electrical connectors.
c. Connect transmission shift linkage.
27. Connect A/C lines at junction near upper torque strut.
28. Connect upper A/C line to A/C condenser.
29. Install upper and lower radiator hoses.





30. Install upper radiator closure panel and center brace (Fig. 18).
31. Install grille.
32. Connect fuel line and heater hoses.
33. Connect coolant reserve/recovery hose to coolant outlet connector.
34. Connect brake booster vacuum hose to intake manifold.
35. Connect the proportional purge hose to throttle body
36. Install all ground straps and connect engine wiring harness.
37. Position PDC and install bolts (Fig. 5). Connect positive battery cable to PDC and ground wire to vehicle body
38. Connect engine wiring harness at Powertrain Control Module (PCM).
39. Connect throttle and speed control cables.
40. Install battery tray and battery.
41. Connect cables to battery.
42. Install air cleaner housing assembly and connect clean air hose.
43. Install oil filter. Fill engine crankcase with proper oil to correct level.
44. Fill power steering system.
45. Fill cooling system.
46. Evacuate and recharge A/C system.
47. Start engine and run until operating temperature is reached.
48. Perform torque strut adjustment procedure.
49. Adjust transmission linkage, if necessary.