With Manual Transmission
NOTE: The engine removal and installation procedures are for the engine only, without the transmission attached.REMOVAL
1. Before servicing the vehicle, fuel pressure must be relieved from the fuel system as follows:
a. Locate, then disconnect either fuel pump, inertia switch or inline high pressure fuel pump electrical connector.
b. Crank engine for approximately ten seconds. Engine may start and operate for a short time. If so, crank engine an additional five seconds after engine stalls.
c. Connect electrical connector disconnected in step a.
2. Drain the cooling system and the crankcase, mark hinge alignment and remove hood
3. Disconnect the battery and ground cables from the cylinder block.
4. Remove the air intake duct assembly, including the crankcase ventilation hose and carbon cannister hose.
5. Disconnect the radiator lower and upper hose at the radiator.
6. If equipped, discharge the A/C system and remove the A/C condenser. Disconnect A/C lines at the compressor.
7. Remove the fan shroud and position it over the fan. Remove the radiator. Remove the fan shroud, fan spacer, belts and pulley.
8. Remove the alternator bolts and allow the alternator to swing down and out of the way.
9. Disconnect the oil pressure sending unit wire from the sending unit, and the flexible fuel line at the fuel tank line. Plug the fuel tank line. Disconnect evaporative emission hoses at the evaporative canister.
10. Disconnect the power brake booster vacuum hose, the accelerator cable from the throttle body, and the speed control linkages,
11. Disconnect the heater hoses from the water pump and intake manifold. Disconnect the water temperature sending unit wire from the sending unit.
12. Remove the flywheel housing-to-engine upper bolts.
13. Disconnect the engine wire loom and position out of the way. Disconnect the ground strap from the cylinder block.
14. Raise the front of the vehicle. Disconnect the starter cable and remove the starter.
Engine Front Supports:
15. Disconnect the muffler inlet pipes and exhaust heat control valve, if equipped, from the exhaust manifolds. Disconnect the engine support insulators from the brackets on the frame underbody and remove the remaining flywheel housing-to-engine bolts.
16. If equipped, disconnect A/C compressor magnetic clutch lead wire.
17. Lower the vehicle, and support the transmission. Install Engine lifting Bracket Tool T70P-6000 or equivalent on the intake manifold. Then, attach the engine crane to the lifting bracket.
18. Raise the engine slightly and carefully pull it from the transmission. Carefully lift the engine out of the engine compartment so that the rear components are not bent or damaged. Install the engine on a work stand.
INSTALLATION
1. Attach the engine crane to the lifting bracket. Remove the engine from the workstand.
2. Lower the engine carefully into the engine compartment. Make sure the dowels in the block are through the rear cover plate, then engage the holes in the flywheel housing.
3 Start the transmission main drive shaft into the clutch disc. It may be necessary to adjust the position of the transmission in relation to the engine if the input shaft will not enter the clutch disc. If the engine hangs up after the shaft enters, turn the crankshaft slowly (transmission in gear) until the shaft splines mesh with the clutch disc splines.
4. Install the flywheel housing upper bolts.
5. Install the engine support insulator-to-bracket washers and attaching nuts, torque nuts to 88-115 Nm (65-85 ft lb). Disconnect the engine crane and remove the lifting bracket.
6. Raise the front of the vehicle. Connect both exhaust manifolds to the muffler inlet pipes and tighten bolts to 34-52 Nm (25-38 ft lb). If equipped, install exhaust heat control valve to exhaust manifold.
7. Position and install the starter and the starter cable.
8. Install the remaining transmission housing-to-engine bolts.
9. Remove the support from the transmission and lower the vehicle.
10. If equipped, connect the A/C compressor magnetic clutch lead wire.
11. Connect the engine wire loom and the water temperature sending unit wire.
12. Connect the bellcrank/linkage bracket to the intake manifold. Connect the transmission shift rod or cable, if equipped. Install the retracting spring. Connect the accelerator rod and speed control linkage, if equipped.
13. Remove the plug from the fuel tank line and connect the fuel line and the oil pressure sending unit wire. Reconnect evaporative emission hoses at the evaporative canister.
Belt Routing Pattern:
14. Install the pulley, drive belt, spacer and fan. Position the fan shroud over the fan.
15. Position the alternator and tighten the alternator adjusting arm bolt 33-60 Nm (24-40 ft lb). Connect the battery ground cable.
16. If equipped, connect two A/C lines to the A/C compressor.
17. Install the radiator and tighten fasteners to 11-14 Nm (8-11 ft lb) and connect the radiator upper and lower hoses. Install the fan shroud and tighten fasteners to 5.4-8 Nm (4-6 ft lb).
18. If equipped, install the A/C condenser to the radiator.
19. Connect the heater hoses at the water pump and intake manifold. Fill and bleed the cooling system. Fill the crankcase with the proper grade and quantity of oil. Connect the power brake booster vacuum hose, if equipped.
20. Operate the engine at fast idle and check all gaskets and hose connections for leaks.
21. Install the air cleaner and intake duct assembly including the crankcase ventilation hose and carbon cannister hose.
22. Evacuate and charge the A/C system, if equipped.
23. Install hood.