Engine: Service and Repair

Engine Removal and Installation

Removal
1. Remove the fuel pump fuse.
2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.
3. Remove the hood.
4. Drain the engine oil.





5. Disconnect the negative battery cable.
6. Discharge the Air Conditioning (A/C) system, if equipped.
7. Disconnect the Manifold Air Temperature (MAT) sensor connector.
8. Remove the air cleaner outlet hose from the throttle body and air cleaner housing.
9. Disconnect the breather tubes from the camshaft cover.
10. Remove the right front wheel.
11. Remove the right front wheel well splash shield.





12. Remove the serpentine accessory drive belt.
13. Drain the engine coolant.
14. Remove the cooling system radiator and the engine cooling fans.
15. Disconnect the upper radiator hose from the thermostat housing.
16. Disconnect the power steering return hose from the power steering pump.
17. Disconnect the power steering pressure hose from the power steering pump.





18. Disconnect the electrical connector at the Direct Ignition System (DIS) coil and the Electronic Control Module (ECM) ground terminal and at the starter motor.
19. Disconnect the oxygen (O2) sensor connector, if equipped.
20. Disconnect the Idle Air Control (IAC) valve connector.
21. Disconnect the Throttle Position Sensor (TPS) connector.
22. Disconnect the engine Coolant Temperature Sensor (CTS) connector.





23. Disconnect the generator voltage regulator connector and power lead.
24. Disconnect all of the necessary vacuum lines, including the brake booster vacuum hose.
25. Disconnect the fuel return line at the fuel rail.
26. Disconnect the fuel feed line at the fuel rail.





27. Remove the fuel rail and injector channel cover as an assembly.
28. Disconnect the throttle cable from the throttle body and the intake manifold bracket.
29. Disconnect the coolant hose at the throttle body.
30. Disconnect the heater outlet hose at the coolant pipe.
31. Disconnect the coolant bypass hose from the cylinder head.
32. Disconnect the surge tank coolant hose from the coolant pipe.
33. Disconnect the lower radiator hose from the coolant pipe.
34. Disconnect the starter solenoid "S" terminal wire and power lead.
35. Remove the A/C compressor.





36. Remove the exhaust flex pipe retaining nuts from the exhaust manifold studs.
37. Remove the exhaust flex pipe retaining nuts from the catalytic converter or the connecting pipe.





38. Remove the exhaust flex pipe.
39. Remove the crankshaft pulley bolts.
40. Remove the crankshaft pulley.
41. Disconnect the vacuum lines at the charcoal canister purge solenoid.
42. Disconnect the electrical connector at the Charcoal Canister Purge (CCP) and the Exhaust Gas Recirculation (EGR) solenoid.
43. Disconnect the electrical connector at the oil pressure switch.
44. Disconnect the Crankshaft Position Sensor (CPS) connector.





45. Disconnect the knock sensor connector.
46. Remove the lower reaction rod bracket bolts.
47. Remove the lower reaction rod bracket.
48. Remove the lower reaction rod mount bolt.





49. Remove the lower reaction rod mount.
50. Remove the rubber cover as a service hole.
51. Remove the transaxle torque converter bolts through the service hole, if automatic transaxle equipped.
52. Remove the transaxle bell housing bolts and the oil pan flange bolts.
53. Support the transaxle with a floor jack.
54. Install the engine lifting device.





55. Disconnect the right engine mount bracket from the engine mount by removing the retaining bolt.
56. Remove the right engine mount bracket from the engine block and frame mount.





57. Separate the engine block from the transaxle. Remove the engine.

Installation
1. Install the engine into the engine compartment.
2. Align the engine alignment pins to the transaxle.
3. Install the transaxle bell housing bolts.
Tighten: Tighten the transaxle bell housing bolts to 75 Nm (55 ft. lbs.).





4. Install the oil pan flange-to-transaxle bolts.
Tighten: Tighten the oil pan flange-to-transaxle bolts to 40 Nm (30 ft. lbs.).
5. Install the right engine mount to the engine block mount and the frame mount.





6. Install the right engine mount bracket retaining bolts and nuts.
Tighten: Tighten the engine mount bracket retaining bolts and nuts to 55 Nm (41 ft. lbs.).
7. Remove the floor jack used for support of the transmission.
8. Remove the engine lifting device.
9. Install the transaxle torque converter bolts, if automatic transaxle equipped.
Tighten: Tighten the transaxle torque converter bolts to 60 Nm (44 ft. lbs.).





10. Install the rubber cover as a service hole.
11. Install the lower reaction rod mount.
12. Install the lower reaction rod mount bolt.
Tighten: Tighten the lower reaction rod mount bolt to 55 Nm (41 ft. lbs.).
13. Install the lower reaction rod bracket.





14. Install the lower reaction rod bracket bolts.
Tighten: Tighten the lower reaction rod bracket bolt to 69 Nm (49 ft. lbs.).
15. Connect the vacuum lines at the CCP solenoid.
16. Connect the electrical connector to the CCP and the EGR solenoid.
17. Connect the oil pressure switch connector.
18. Install the crankshaft pulley.





19. Install the crankshaft pulley bolts.
Tighten: Tighten the crankshaft pulley bolts to 20 Nm (15 ft. lbs.) using a torque wrench.
20. Connect the CPS connector.
21. Install the exhaust flex pipe.





22. Install the exhaust flex pipe retaining nuts to the exhaust manifold studs.
Tighten: Tighten the exhaust flex pipe-to-exhaust manifold retaining nuts to 35 Nm (26 ft. lbs.).
23. Install the exhaust flex pipe retaining nuts to the catalytic converter or the connecting pipe.
Tighten: Tighten the exhaust flex pipe-to-catalytic converter or connecting pipe retaining nuts to 35 Nm (26 ft. lbs.).
24. Connect the power steering pressure hose.
25. Connect the power steering return hose.





26. Install the A/C compressor, if equipped.
27. Install the serpentine accessory drive belt.
28. Install the right front wheel well splash shield.
29. Install the right front wheel.
30. Connect the fuel feed line to the fuel rail.
31. Connect the fuel return line to fuel rail.





32. Install the fuel rail and injector channel cover as an assembly.
33. Connect all of the necessary vacuum lines including the brake booster vacuum hose.
34. Connect the O2 sensor connector, if equipped.
35. Connect the starter solenoid "S" terminal wire and power lead.
36. Connect the generator voltage regulator connector.
37. Connect the CTS connector.
38. Connect the engine CTS connector.
39. Connect the TPS connector.
40. Connect the IAC valve connector.
41. Connect the MAP sensor connector.





42. Connect the knock sensor, if necessary.
43. Connect the electrical connector at the DIS ignition coil and the ECM ground terminal and at the starter motor.
44. Install the air cleaner outlet hose between the throttle body and the air cleaner housing.
45. Connect the breather tubes to the camshaft cover.
46. Connect the MAT sensor connector.





47. Install the cooling system radiator and the engine cooling fans.
48. Connect the lower radiator hose to the coolant pipe.
49. Connect the upper radiator hose to the thermostat housing.
50. Connect the heater inlet hose to the cylinder head.
51. Connect the heater outlet hose to the coolant pipe.
52. Connect the coolant surge tank hose to the coolant pipe.





53. Connect the coolant hose to the throttle body.
54. Connect the throttle cable to the throttle body and the intake manifold bracket.
55. Install the fuel pump fuse.
56. Connect the negative battery cable.
57. Refill the engine crankcase with engine oil.
58. Refill the engine coolant system.
59. Bleed the power steering system.
60. Refill the A/C refrigerant system, if equipped.





61. Install the hood.