Engine: Service and Repair

REMOVAL AND INSTALLATION
1. Disconnect battery ground cable, then drain cooling system.
2. Disconnect underhood lamp electrical connector, then mark position of hood hinges and remove hood.
3. Remove cowl top vent panel.
4. Disconnect alternator and voltage regulator wiring harness.
5. Remove air cleaner assembly.
6. Remove upper radiator hose, then the heater hoses.
7. Disconnect transaxle oil cooler tubes using line disconnect tool No. T86P-77265-AH or equivalent.
8. Discharge A/C, then disconnect manifold assembly from compressor.
9. Remove accelerator cable mounting bracket.
10. Relieve fuel system pressure.
11. Disconnect engine control sensor electrical connector, then remove bolt holding electrical harness bracket.
12. Disconnect vacuum hoses and ground wire assembly.
13. Disconnect bulkhead electrical connector, then transaxle pressure switches.
14. Disconnect throttle control valve cable.
15. Raise and support vehicle.
16. Drain engine oil and remove oil filter.
17. Remove wheel and tire assemblies.
18. Without disconnecting brake fluid lines, remove brake calipers, support and position aside.
19. Disconnect anti-lock brake wiring connectors at wheel sensors.
20. Disconnect heated exhaust gas oxygen sensors.

Fig. 2 Converter Y Pipe Removal:

21. Remove converter Y pipe retainer bolts, then install exhaust connector holder tool No. T94T-6000-AH or equivalent and remove converter Y pipe Fig. 2
22. Disconnect heated oxygen sensor wiring from body.
23. Disconnect power steering fluid cooler lines, then remove steering shaft to steering gear pinch bolt and disconnect shaft from gear.
24. Lower vehicle, then disconnect upper strut to body retaining bolts.
25. Raise and support vehicle, then position suitable jack with engine support table under subframe assembly, engine and transaxle.
26. Remove four subframe mounting bolts, then lower subframe assembly with engine and transaxle from body.
27. Install suitable lifting eyes to engine, then using suitable lifting equipment, lift engine, transaxle and subframe assembly from engine table and jack.
28. Disconnect stabilizer bar links from strut assemblies, then disconnect drive axles from transaxle.
29. Disconnect power steering lines from power steering gear.
30. Remove engine and transaxle to subframe mounting nuts and bolts, then lift engine and transaxle from subframe.
31. Remove starter, then remove torque converter cover and disconnect torque converter from engine drive plate.
32. Disconnect engine to transaxle electrical connectors.
33. Remove transaxle mount and engine support frame.
34. Remove engine to transaxle bolts, then separate engine and transaxle.
35. Remove engine assembly.
36. Reverse procedure to install, noting the following:
a. Tighten to specifications.
b. Recharge A/C.
c. Bleed power steering.
d. Bleed cooling system.
e. Verify that front wheel alignment is within specifications.
f. Check all fluid levels.