Engine: Service and Repair

1. Disconnect battery ground cable.
2. Mark hood hinge location, disconnect ground strap near right hinge and remove hood.
3. Using vacuum pump D80P-250-A or equivalent, release pressure from EFI fuel system at fuel pressure regulator valve.
4. Remove cap from cooling system expansion tank and drain coolant.
5. Disconnect radiator upper hose from radiator, then on vehicles equipped with manual transmission, disconnect radiator air vent hose from radiator.
6. Remove radiator upper attaching bolts and disconnect cooling fan electrical connector.
7. Remove oil dipstick.
8. Disconnect vacuum hose from EGR valve.
9. Disconnect fuel injector electrical connector located between upper intake manifold and oil dipstick.
10. Carefully disconnect electrical connectors from EEC-IV engine coolant temperature sensor, engine knock sensor, oil pressure sending unit, cooling fan temperature switch, throttle air bypass valve and the throttle position sensor. When disconnecting EEC-IV system related component electrical connectors, ensure that vehicle battery ground cable is disconnected to avoid serious EEC-IV system and related component damage.
11. Disconnect fuel line from pulse damper.
12. Using tool No. T82L-9500-AH or equivalent, disconnect fuel return line.
13. Disconnect throttle cable and, if equipped, the transmission kickdown cable.
14. Remove accelerator cable bracket attaching screws and the bracket from the upper intake manifold, then position bracket and accelerator cable, and transmission kickdown cable if equipped, out of way.
15. Disconnect supply hose from vacuum tree located on dash panel.
16. Disconnect electrical connector from distributor TFI module.
17. Remove alternator from mounting bracket and secure out of way.
18. Remove power steering pump from mounting bracket and secure out of way.
19. Remove turbocharger air inlet tube and disconnect orange ground wire from turbocharger air inlet elbow.
20. Disconnect electrical connector from exhaust gas oxygen sensor and the vacuum hose from the turbocharger air inlet elbow.
21. Remove A/C compressor from its mounting bracket and secure out of way.
22. On vehicles equipped with automatic transmission, remove transmission dipstick tube attaching nut at turbocharger outlet flange.
23. On all vehicles, disconnect coolant supply and return hoses from heater control valve.
24. On vehicles equipped with automatic transmission, disconnect transmission oil cooling lines from radiator.
25. On all vehicles, raise and support vehicle.
26. On vehicles equipped with manual transmission, disconnect radiator refill tube at refill hose.
27. On all vehicles, disconnect radiator lower hose from radiator, then remove bolts attaching radiator to side rail and remove radiator through bottom of vehicle.
28. Remove bolt attaching chassis ground wire to A/C compressor bracket, then remove starter.
29. Remove nuts attaching catalytic converter inlet pipe to turbocharger.
30. Remove catalytic converter to converter inlet pipe flange attaching bolts and the catalytic converter support bracket bolt.
31. Remove inlet pipe.
32. On vehicles equipped with manual transmission, remove bolt attaching engine rear cover to flywheel housing.
33. On vehicles equipped with automatic transmission, remove torque converter to drive plate attaching nuts through starter opening. To bring bolts into position, turn crankshaft with ratchet handle and socket applied to crankshaft pulley attaching bolt. Always turn crankshaft clockwise. Counterclockwise rotation may cause timing belt to jump time.
34. On all vehicles, remove stud nuts attaching engine mounts to cross member.
35. Remove converter/flywheel housing attaching bolts. If removal of bolts at top of housing is prevented by contact with body, leave them loose and in position. If necessary, to gain access to housing to engine bolts, support transmission with jack and remove nuts securing transmission mount to underbody. Remove nuts securing driveshaft center bearing support to underbody. Lower transmission and remove converter/flywheel housing to engine bolts, then raise transmission and secure transmission mount to underbody.
36. Lower vehicle.
37. Install engine lifting device on engine lifting attachments.
38. Support transmission with jack and raise engine until front support lower studs clear crossmember.
39. Remove bolts attaching front support brackets to engine and remove mounts and brackets as assemblies.
40. Pull engine forward to separate it from transmission, then carefully raise engine out of engine compartment.
41. Reverse procedure to install.