Removal and Installation

REMOVAL

Figure 27-Negative Cable-Disconnect:

1. Disconnect negative cable at right strut tower.
2. Mark hood position at hinges and remove hood.
3. Remove both wiper arms.

Figure 28-Cowl Covers:

4. Remove both cowl covers.

Figure 29 Cowl Support:

5. Remove cowl support.

Figure 30-Air Cleaner With Inlet Hose:

6. Remove air cleaner assembly with air inlet hose.
7. Remove upper radiator crossmember.
8. Disconnect hood release cable from hood latch.
9. Remove fan module.
10. Drain cooling system. Refer to Cooling System.
11. Remove A/C and accessory drive belts. Refer to Cooling System.
12. Disconnect upper radiator hose at engine.
13. Disconnect lower radiator hose at radiator.
14. Disconnect engine oil and transmission cooler lines at radiator.
15. Remove power steering line bracket at left side of radiator.
16. Remove fasteners attaching air conditioning condenser to radiator.
17. Remove Radiator.
18. Remove generator.
19. Remove power steering pump mounting bolts and set pump aside.
20. Remove air conditioning compressor mounting bolts and set aside.
21. Loosen and remove V-Band clamp at right exhaust manifold.
22. Remove front and rear support bracket fasteners attaching right side catalytic converter down pipe.
23. Release fuel pressure.
24. Disconnect fuel line.
25. Disconnect throttle and speed control cables from bracket.
26. Disconnect both hoses at coolant bottle.
27. Disconnect all vacuum hoses.
28. Disconnect ground straps at both cylinder heads.

CAUTION: Intake manifold is a composite design, and should be removed before lifting engine or damage to the manifold could occur.

29. Remove upper intake manifold. Cover intake manifold openings with tape.
30. Disconnect heater hoses.
31. Remove rear throttle body support bracket.
32. Remove fastener for water pipe at transmission to block bolt.
33. Remove four upper transmission to block bolts.
34. Disconnect all electrical connections.
35. Hoist vehicle.
36. Drain engine oil.
37. Remove structural collar and mark flex plate to torque converter position.
38. Remove bolts holding torque converter to flex plate.
39. Disconnect both transmission oil cooler line brackets from engine.
40. Loosen and remove left exhaust manifold V-Band clamp.
41. Loosen the left converter down pipe at band clamp, and front and rear support brackets for starter removal.
42. Remove starter.
43. Remove left engine mount bolts.
44. Remove right engine mount bolts.
45. Remove crankshaft position sensor.
46. Remove two lower transmission to block bolts.
47. Lower vehicle.
48. Attach lifting device to engine.
49. Insert floor jack with small block of wood under transmission pan to support transmission.
50. Hoist engine from engine compartment.

INSTALLATION
1. Attach lifting device and lower engine into engine compartment.
2. Align engine mounts and install fasteners but do not tighten until all mounting bolts have been installed.
3. Install transmission case to engine block tighten bolts to 102 Nm (75 ft. lbs.).
4. Remove engine lifting device.
5. Raise vehicle.
6. Tighten engine mount fastener to 61 Nm (45 ft. lbs.).
7. Align flex plate to torque converter and install mounting bolts tighten to 75 Nm (55 ft. lbs.).
8. Install crankshaft position sensor.
9. Install starter.
10. Install new V-Band clamp at left side exhaust manifold to catalytic converter. Tighten V-Band clamp to 11 Nm (100 inch lbs.).
11. Install and tighten left side front and rear catalytic converter down pipe support bracket fasteners.
12. Tighten the left converter down pipe band clamp,
13. Install the transmission oil cooler lines bracket to engine.
14. Install structural collar.
15. Lower vehicle.
16. Connect all electrical connections.
17. Install four upper transmission to block bolts tighten to 102 Nm (75 ft. lbs.).
18. Install water pipe fastener to transmission case to cylinder block bolt.
19. Install rear throttle body support bracket.
20. Connect heater hoses.
21. Install intake manifold.
22. Connect ground straps at both cylinder heads.
23. Connect all vacuum hoses.
24. Connect both hoses at coolant bottle.
25. Connect throttle and speed control cables to bracket and throttle arm.
26. Connect fuel line.
27. Install new V-Band clamp at right exhaust manifold. Tighten V-Band clamp to 11 Nm (100 inch lbs.).
28. Install and tighten right side front and rear catalytic converter down pipe support bracket fasteners.
29. Install air conditioning compressor and tighten fasteners to 28 Nm (250 inch lbs.).
30. Install power steering pump and tighten fasteners to 28 Nm (250 inch lbs.).
31. Install generator.
32. Install radiator.
33. Attach air conditioning condenser to radiator.
34. Install power steering line bracket to radiator.
35. Connect engine oil and transmission cooler lines to radiator.
36. Install lower radiator hose.
37. Install upper radiator hose.
38. Install A/C and accessory drive belts. Refer to Cooling System.
39. Install fan module.
40. Fill cooling system. Refer to Cooling System .
41. Fill engine with proper amount of oil.
42. Connect hood release cable to hood latch and install upper radiator crossmember.
43. Install air cleaner and air inlet hose.
44. Install cowl support.
45. Install both cowl covers.
46. Install both wiper arms.
47. Install hood.
48. Connect negative cable at right strut tower.