Removal and Replacement
REMOVAL
1. Remove the cowl grille (4), and cross-bar beam. Unibody
1. Perform the Fuel System Pressure Release procedure. Fuel Pressure Release
3. Disconnect the battery negative cable. Battery
4. Remove the air cleaner resonator and duct work as an assembly.
5. Remove the wiper module. Service and Repair
6. Drain cooling system. Service and Repair
1. GENERATOR
2. IDLER PULLEY
3. POWER STEERING PUMP
4. GA/C COMPRESSOR
5. CRANKSHAFT
6. BELT TENSIONER
7. WATER PUMP
7. Remove the accessory drive belt. Drive Belts, Mounts, Brackets and Accessories
8. Remove the viscous fan/drive. Radiator Cooling Fan
9. Remove the upper crossmember and top core support. Service and Repair
10. Remove the condenser. Condenser HVAC
11. Remove radiator. Service and Repair
12. Evacuate the refrigerant. Service and Repair
13. Remove the A/C compressor (2) with the lines attached. Secure compressor out of the way. Service and Repair
1. MOUNTING BOLT
2. GENERATOR
3. MOUNTING STUD/BOLT
14. Remove generator assembly. Service and Repair
15. Remove the intake manifold and IAFM as an assembly. Service and Repair
16. Disconnect the heater hoses. Coolant Line/Hose
Note: It is not necessary to disconnect P/S hoses from pump, for P/S pump removal.
17. Remove the power steering pump and set aside. Service and Repair
18. Disconnect the fuel supply line. Service and Repair
19. Raise and support the vehicle on a hoist and drain the engine oil.
20. Remove engine front mount thru-bolt nuts (3).
21. Disconnect the transmission oil cooler lines from their retainers at the oil pan bolts. Service and Repair
22. Disconnect exhaust pipe at manifolds. Service and Repair
1. STARTER
2. BOLTS
23. Disconnect the starter wires. Remove starter motor. Service and Repair
1. BOLT
2. BOLT
3. BOLT
24. Remove the structural dust cover and transmission inspection cover. Service and Repair
1. ENGINE
2. BOLTS
3. TRANSMISSION
25. Remove drive plate to converter bolts (Automatic transmission equipped vehicles).
26. Remove transmission bell housing to engine block bolts (2).
1. BOLTS
2. ENGINE LIFT FIXTURE
3. ADAPTER BOLT
4. ADAPTER
5. ADAPTER NUT
27. Install engine lift fixture (2), special tool # 8984. Do not use adapter (4)..
28. Install engine lift fixture, special tool # 8984.
29. Separate engine from transmission, remove engine from vehicle, and install engine assembly on a repair stand.
INSTALLATION
1. BOLTS
2. ENGINE LIFT FIXTURE
3. ADAPTER BOLT
4. ADAPTER
5. ADAPTER NUT
1. Install engine lift fixture (2), Special tool # 8984. Do not use adapter (4).
2. Position the engine in the engine compartment.
1. ENGINE
2. BOLTS
3. TRANSMISSION
3. Lower engine into compartment and align engine with transmission:
- Manual Transmission: Align clutch disc assembly (if disturbed). Install transmission input shaft into clutch disc while mating engine and transmission surfaces. Install two transmission to engine block mounting bolts finger tight.
- Automatic Transmission: Mate engine and transmission and install two transmission to engine block mounting bolts finger tight.
4. Lower engine assembly until engine mount through bolts rest in mount perches.
5. Position the thru-bolt into the support cushion brackets.
6. Install remaining transmission to engine block mounting bolts (2) and tighten.
7. Tighten engine mount through bolts (3).
8. Install drive plate to torque converter bolts. (Automatic transmission models)
1. BOLT
2. BOLT
3. BOLT
9. Install the structural dust cover and transmission dust cover.
1. STARTER
2. BOLTS
10. Install the starter (1) and connect the starter wires. Service and Repair
11. Install exhaust pipe to manifold.
12. Lower the vehicle.
1. BOLTS
2. ENGINE LIFT FIXTURE
3. ADAPTER BOLT
4. ADAPTER
5. ADAPTER NUT
13. Remove engine lift fixture (2), special tool # 8984.
14. Connect the fuel supply line. Service and Repair
15. Reinstall the power steering pump. Service and Repair
16. Connect the heater hoses.
17. Install the intake manifold. Service and Repair
1. MOUNTING BOLT
2. GENERATOR
3. MOUNTING STUD/BOLT
18. Using a new gasket, install throttle body. Service and Repair
19. Install the generator (2) and wire connections. Service and Repair
20. Install a/c compressor (2) and lines. Service and Repair
1. GENERATOR
2. IDLER PULLEY
3. POWER STEERING PUMP
4. GA/C COMPRESSOR
5. CRANKSHAFT
6. BELT TENSIONER
7. WATER PUMP
21. Install the accessory drive belt. Service and Repair
22. Install radiator. Service and Repair
23. Connect the radiator lower hose.
24. Connect the transmission oil cooler lines to the radiator. Service and Repair
25. Install the fan shroud.
26. Install the fan.
27. Connect the radiator upper hose.
28. Install the condenser. Service and Repair
29. Install upper radiator support crossmember. Service and Repair
30. Install the washer bottle.
31. Charge the refrigerant. Service and Repair
32. Install the cowl grill (4), and crossbar beam. Service and Repair
33. Install the air cleaner resonator and duct work.
34. Add engine oil to crankcase. Specifications
35. Fill cooling system. Service and Repair
36. Install the wiper module. Service and Repair
37. Connect battery negative cable. Service and Repair
38. Start engine and inspect for leaks.
39. Road test vehicle.