Engine Removal and Installation

Fig. 1 Engine Mount Assembly:

1. Relieve fuel system pressure as described see Fuel Pressure Relief. Under Powertrain Management/Computers and Control Systems/System Diagnosis/Procedures/Diagnostic Charts/A Charts/Chart A-7 Fuel System Diagnosis.
2. Disconnect battery ground cable.
3. Remove top half of air cleaner assembly and throttle body duct.
4. Drain cooling system.
5. Disconnect upper radiator hose from engine and position aside.
6. Disconnect lower radiator hose from engine and position aside.
7. Disconnect coolant inlet line from surge tank.
8. Disconnect following vacuum hoses:
a. Vacuum modulator.
b. EVAP canister purge.
c. Power brake booster line.
9. Disconnect heater outlet hose from water pump.
10. Remove serpentine drive belt.
11. Disconnect accelerator and cruise control cable from throttle linkage.
12. Remove upper wiring from engine as follows:
a. Electronic ignition.
b. Heated oxygen sensor.
c. Injector harness.
d. IAC.
e. Throttle position sensor.
f. Engine coolant temperature sensor.
g. Park/Neutral position switch.
h. Transaxle shift solenoid and TCC solenoid.
i. EGR.
j. Ground at transaxle.
13. Remove alternator as described under Alternator. refer to Starting and Charging.
14. Disconnect power steering lines at power steering pump.
15. Disconnect fuel lines.
16. Remove cooling fan assembly.
17. Disconnect shift cable linkage and cable from mounting bracket. Transaxle should be in low gear for better accessibility.
18. Disconnect transaxle vent tube from transaxle.
19. Disconnect vacuum hose at vacuum reservoir.
20. Remove engine support fixture.
21. Loosen but do not remove top two A/C compressor bolts.
22. Raise and support vehicle.
23. Remove front tire and wheel assemblies.
24. Remove right and left splash shields.
25. Remove engine mount strut as described under Engine Mount Strut. Refer to Engine/Drive Belts, Mounts, Brackets and Accessories.
26. Remove both front ABS speed sensor connectors and harness from suspension supports.
27. Remove both ball joints.
28. Remove suspension support assembly.
29. Remove drive axles from transaxle and support.
30. Remove oil filter and adapter.
31. Remove transaxle converter cover.
32. Remove starter as described under Starter Motor. Refer to Starting and Charging/Starting System.
33. Disconnect lower engine wiring as follows:
a. Knock sensor.
b. Front crankshaft position sensor.
c. Side crankshaft position sensor.
d. Oil level sensor.
e. VSS.
f. Transaxle ground.
34. Disconnect heater hoses.
35. Remove A/C compressor lower bolts, then position compressor aside.
36. Remove vacuum reserve tank.
37. Remove exhaust pipe from manifold and position aside.
38. Remove engine mount strut bracket.
39. Disconnect transaxle cooling lines at radiator.
40. Remove fluid level indicator and tube.
41. Lower vehicle and engine/transaxle onto suitable table.
42. Remove transaxle mount to body bolts, Fig. 1.
43. Remove intermediate bracket from right engine mount support bracket.
44. Raise and support vehicle, leaving powertrain on table.
45. Separate engine and transaxle assembly.
46. Reverse procedure to install, noting the following:
a. After connecting engine to transaxle, loosely install serpentine drive belt to hold engine design together.
b. Tighten engine fasteners and components to specifications.
c. Bleed power steering system after engine installation.