Engine: Service and Repair

1. Disconnect battery ground cable.
2. Drain cooling system, then remove air cleaner outlet tube and engine air cleaner.
3. Discharge air conditioning system, then remove fan blade and fan shroud.
4. Relieve fuel system pressure and disconnect fuel lines.
5. Disconnect 42-pin connector and 8-pin connector and secure clear of engine.
6. Disconnect accelerator cable and speed control actuator with a screwdriver.
7. Disconnect throttle valve control actuating cable.
8. Disconnect electrical connector and vacuum hose from canister purge solenoid.
9. Disconnect power supply from power distribution box and starter relay.
10. Disconnect vacuum supply hose from throttle body adapter vacuum port.
11. Disconnect transmission oil cooler tubes from transmission oil cooler, then disconnect upper radiator hose from outlet tube.
12. Disconnect heater supply and return hoses.
13. Disconnect A/C compressor inlet and outlet hoses from A/C compressor using spring coupling disconnect tool T81P-19623-G1 and T81P-19623-G2 or equivalents.
14. Disconnect engine to frame wire and body ground strap from dash panel, then partially raise vehicle on a hoist and remove front wheels.
15. Disconnect right and left front anti-lock sensor and brackets wiring connectors.
16. Remove right and left front disc brake caliper bolts. Remove front disc brake calipers and secure to vehicle with wire.

CAUTION: Do not allow calipers to suspend from brake hoses.

17. Disconnect right and left front suspension upper arms from front wheel spindles.
18. Disconnect front spring and shocks from front suspension lower arms.
19. Raise vehicle and drain engine oil, then disconnect dual converter Y pipe from exhaust manifolds and resonator.
20. Disconnect transmission shift cable and bracket.
21. Mark relationship of driveshaft centering socket yoke to rear axle universal joint flange.
22. Remove four bolts connecting driveshaft centering socket yoke to rear axle universal joint flange. Support rear axle assembly with suitable jack stand.
23. Remove two nut and bolt assemblies retaining the front of the rear axle assembly to the rear sub-frame.
24. Loosen rear differential bracket to body bolts and lower from vehicle.
25. Slide driveshaft rearward until it is clear of extension housing, then remove lower radiator hose from radiator inlet tube.
26. Loosen spring clamps and remove power steering hoses from power steering oil cooler. Disconnect wiring connector bulkhead.
27. Support front sub-frame using Rotunda Powertrain Lift Tool 014-00765 and Adapter tool 014-00341 or equivalents.
28. Remove rear engine support insulator retaining bolts, then disconnect steering coupling at pinch bolt joint.
29. Remove eight front sub-frame bolts.
30. Lower engine and transmission from vehicle.
31. Disconnect power steering pressure and return hoses from power steering pump.
32. Remove engine wire harness retainers from front sub-frame.
33. Remove left and right front engine support insulator through bolts.
34. Install Rotunda Engine Lift Bracket 014-00334 or equivalent, on side of LH cylinder head at front.
35. Attach Rotunda Engine Lift Brackets 014-00334 or equivalent, then install Rotunda Engine Lift Brackets on side of right cylinder head at rear.
36. Connect Rotunda Floor Crane tool 077-00043 or equivalent, to Engine Lift Brackets.
37. Remove starter motor, then the transmission oil cooler tubes.
38. Remove retaining nut from transmission line stud to cylinder block.
39. Remove transmission housing cover from cylinder block to access torque converter retaining nuts. Rotate crankshaft until each nut is accessible and remove nuts.
40. Lower engine and transmission assembly, then disconnect transmission wire harness connectors at transmission.
41. Remove six bolts retaining transmission to engine. Separate engine from transmission.
42. Reverse procedure to install, noting the following:
a. Align paint marks on flywheel and torque converter when connecting engine to transmission.
b. Fill and bleed cooling system.
c. Evacuate and recharge A/C system.
d. Fill engine with new engine oil.
e. Start engine and check for coolant, oil and fuel leaks.