Removal and Replacement
REMOVAL - ENGINE ASSEMBLY1. Release fuel pressure.
2. Disconnect negative battery cable.
3. Drain cooling system.
4. Discharge A/C system using a suitable refrigerant recovery machine.
5. Remove throttle body air inlet hose and air cleaner housing assembly.
6. Raise vehicle on hoist.
7. Remove both front wheels.
8. Remove left and right splash shields.
9. Remove fasteners attaching lower front fascia to crossmember.
10. Remove fasteners attaching lower air shield to crossmember.
11. Remove front bumper fascia.
12. Lower vehicle.
13. Remove upper radiator crossmember.
14. Disconnect upper and lower radiator hoses at radiator.
15. Automatic Transmission Equipped Vehicles:
^ Using a blade or suitable hose cutter, cut transaxle oil cooler lines off flush with fittings. Plug lines and fittings to prevent debris from entering transaxle or cooler circuit. A service splice kit will be installed upon reassembly
^ Disconnect transmission electrical harness connectors (C104 & C105).
^ Disconnect transmission shift cable.
16. Manual Transmission Equipped Vehicles:
^ Disconnect transmission shift cables and remove from retaining bracket.
^ Disconnect back up lamp switch connector.
17. Disconnect A/C lines at condenser. Remove cooling module (fan, radiator, A/C condenser).
18. Disconnect engine electrical harness from PCM and bulkhead connectors.
19. Remove fasteners attaching ABS brake module to lower radiator crossmember. Support module with a suitable retaining strap.
20. Disconnect brake line from retaining clips that attach to lower radiator crossmember.
21. Raise vehicle.
22. Remove both axle shafts.
23. Remove front engine mount through bolt. Remove front engine mount from lower radiator crossmember.
24. Remove lower radiator crossmember.
25. Remove accessory drive belts.
26. Remove power steering pump and bracket as an assembly. Do not disconnect power steering lines from pump. Reposition pump and support with suitable retaining strap.
27. Disconnect heater return hose from pipe connection at right front frame rail area.
28. Disconnect A/C compressor electrical connector.
29. Remove A/C compressor mounting bolts. Reposition A/C compressor and support with suitable retaining strap. Generator can be removed with engine assembly.
30. Remove structural collar.
31. Remove the exhaust cross-under pipe.
32. Remove rear engine mount and transaxle bracket.
33. Drain engine oil.
34. Automatic Transmission Equipped Vehicles:
^ Remove transaxle torque converter housing cover.
^ Mark flex plate to torque converter position. Remove torque converter bolts.
35. Manual Transmission Equipped Vehicles:
^ Using Special Tool 6638, disconnect clutch hydraulic circuit quick connect fitting.
^ Remove clutch/drive plate inspection cover.
^ Mark flex plate to modular clutch position. Remove modular clutch assembly-to-drive plate bolts.
36. Lower vehicle.
37. Disconnect positive cable from battery and PDC.
38. Disconnect ground cable from left side transaxle mount bracket.
39. Disconnect throttle and speed control cables.
40. Disconnect coolant pressure bottle coolant hose from engine coolant outlet connector.
41. Disconnect heater hose from engine coolant outlet connector.
42. Disconnect ground strap at right shock tower.
43. Disconnect fuel line.
44. Disconnect brake booster and vapor purge vacuum hoses.
45. Disconnect all ground straps attaching to engine.
46. Position vehicle height to allow engine dolly 6135 and cradle 6710 with posts 6848 to be installed under vehicle.
47. Loosen cradle engine mounts to allow movement for positioning onto engine locating holes on the engine block, compressor mount bracket and oil pan rail. Lower vehicle and position cradle until the engine is resting on posts (Fig. 6). Tighten post mounts to cradle frame to prevent movement when removing or installing engine/transaxle assembly. Secure engine/transaxle assembly to dolly/cradle with safety straps.
48. Lower vehicle so weight of the engine and transmission ONLY is on the cradle.
49. Remove right and left side engine mount bolts.
50. Slowly raise vehicle in short length spans. Inspect at each interval for potential engine or transaxle contact to vehicle components. Move the cradle/dolly fixture as necessary to allow for removal clearance.
INSTALLATION - ENGINE ASSEMBLY
1. Position engine/transaxle assembly under vehicle and slowly lower vehicle in short length spans. Inspect at each interval for potential engine or transaxle contact to vehicle components. Move the cradle/dolly fixture as necessary to allow for installation clearance (Fig. 6).
2. Continue lowering vehicle until right side engine mount and left side transaxle mount align to their mounting locations. Install mounting bolts and torque to 61 Nm (45 ft. lbs.).
3. Remove safety straps from engine/transaxle assembly. Slowly raise vehicle enough to remove the engine dolly and cradle.
4. Reattach all ground straps to engine.
5. Connect brake booster and vapor purge vacuum hoses.
6. Connect fuel line.
7. Connect ground strap to right shock tower.
8. Connect heater hose to coolant outlet connector.
9. Connect coolant pressure bottle coolant hose to coolant outlet connector.
10. Connect throttle and speed control cables.
11. Connect ground cable to left side transaxle mount bracket.
12. Connect positive cable to battery and PDC.
13. Raise vehicle.
14. Automatic Transmission Equipped Vehicles:
^ Install torque converter bolts.
^ Install torque converter housing cover.
15. Manual Transmission Equipped Vehicles:
^ Install modular clutch assembly-to-drive plate bolts.
^ Install clutch/drive plate inspection cover.
^ Connect clutch hydraulic circuit quick connect fitting.
16. Install rear engine mount and transaxle bracket.
17. Install exhaust cross-under pipe.
18. Install structural collar .
19. Install A/C compressor to bracket.
20. Connect A/C compressor clutch electrical connector.
21. Connect heater return hose to pipe connection at right front frame rail area.
22. Install power steering pump and bracket assembly.
23. Install accessory drive belts.
24. Install lower radiator crossmember.
25. Install front engine mount to lower radiator crossmember. Install front engine mount through bolt.
26. Install both axle shafts.
27. Lower vehicle.
28. Connect brake line to retaining clips that attach to lower radiator crossmember.
29. Install fasteners attaching ABS module to lower radiator crossmember.
30. Connect engine electrical harness to PCM and bulkhead connectors.
31. Automatic Transmission Equipped Vehicles:
^ Connect transmission shift cable.
^ Connect transmission electrical harness connectors (C104 & C105).
^ Connect transmission oil cooler lines using service splice kit. Refer to instructions provided with kit.
32. Manual Transmission Equipped Vehicles:
^ Connect transmission shift cables.
^ Connect back up lamp switch connector.
33. Install cooling module (fan, radiator, A/C condenser). Connect A/C lines to condenser.
34. Connect upper and lower radiator hoses to radiator.
35. Install upper radiator crossmember.
36. Raise vehicle.
37. Ensure oil pan drain plug is tight. Install new oil filter.
38. Install front bumper fascia and lower air shield to lower radiator crossmember.
39. Install left and right splash shields.
40. Install both front wheels.
41. Lower vehicle.
42. Install throttle body air inlet hose and air cleaner housing assembly.
43. Fill engine crankcase with proper oil to correct level.
44. Evacuate and recharge Air Conditioning system.
45. Fill cooling system.
46. Connect negative battery cable.
47. Start engine and run until operating temperature is reached.