Engine: Service and Repair
REMOVAL1. Disconnect battery ground cable and remove hood.
2. Discharge and recover refrigerant from A/C system.
3. Disconnect intake air temperature (IAT) sensor electrical connector.
4. Loosen air cleaner outlet tube clamps and remove air cleaner outlet tube.
5. Remove radiator and A/C condenser core as an assembly.
6. Disconnect positive battery cable.
7. Remove battery heat shield, battery hold-down clamp, then the battery from vehicle.
8. Turn drive belt tensioner clockwise to relieve tension, then remove drive belt.
9. Remove power steering reservoir bolts and position reservoir aside.
10. Remove power steering pump bolts and position pump aside.
11. Disconnect A/C lines from A/C compressor.
12. Disconnect A/C compressor electrical connector.
13. Remove power steering pump and A/C compressor bracket bolts, then the A/C compressor bracket with compressor attached.
14. Use spark plug wire removal tool No. T74P-6666-A or equivalent to remove ignition wires from spark plugs, where possible.
15. Disconnect ignition coil electrical connectors, EGR vacuum regulator solenoid vacuum and electrical connectors.
16. Remove ignition coil bracket with ignition coil and spark plug wires attached.
17. Disconnect alternator electrical connectors.
18. Relieve fuel system pressure, then disconnect fuel lines.
19. Disconnect emissions vapor management hose from upper intake manifold.
20. Remove lower steering column shaft bolt and disconnect lower steering column shaft.
21. Label, then disconnect all vacuum lines.
22. Disconnect crankcase ventilation hose from throttle body.
23. Remove throttle body snow shield bolts and snow shield.
24. Disconnect accelerator cable from throttle body.
25. Remove accelerator cable bracket bolts and position accelerator cable aside.
26. Disconnect powertrain control module chassis wiring harness and ground cable electrical connectors.
27. Disconnect heater hoses from heater core.
28. Raise and support vehicle.
29. Remove power steering cooler nuts and position power steering cooler aside.
30. Remove ground cable on front of engine.
31. Remove battery to starter relay cable from clips on front of engine.
32. Remove transmission cooler line to engine bracket from engine.
33. Disconnect starter electrical connector, and remove starter.
34. Remove transmission inspection shield.
35. Disconnect engine control sensor wiring from transmission.
36. Disconnect LH heated oxygen sensor electrical connector.
37. Remove torque converter nuts.
38. Remove shift cable from transmission.
39. Remove six bell housing bolts.
40. Remove oil bypass filter.
41. Remove lower radiator hose.
42. Remove exhaust inlet pipe to exhaust manifold bolts.
43. Partially lower vehicle to gain access to RH front fender apron.
44. Remove RH front fender apron pushpins and RH front fender apron.
45. Remove RH exhaust manifold bolts.
46. Remove LH front fender apron pushpins and LH front fender apron.
47. Remove LH exhaust manifold bolts.
48. Remove oil level indicator tube.
49. Lower vehicle and support transmission.
50. Remove LH and RH exhaust manifolds.
51. Remove RH and LH engine mount nuts from top of mounts.
52. Install engine lifting brackets, tool No. D94L-6001-B or equivalent, to RH front exhaust manifold bolt positions and to LH rear exhaust manifold bolt positions.
53. Install engine lifting spreader bar tool No. D93P-6001-A3 or equivalent to engine lifting brackets.
54. Remove engine from vehicle.
INSTALLATION
1. Install engine lifting spreader bar tool No. D93P-6001-A3 or equivalent to engine lifting brackets and a suitable engine lifting device.
2. Install suitable engine lifting sling to spreader bar and position around crankshaft vibration damper to support front of engine.
3. Remove engine from engine stand.
4. Lower engine into engine compartment and position upper engine mount brackets over engine mount studs onto engine mounts.
5. Position engine to transmission, then remove engine lifting equipment.
6. Raise and support vehicle.
7. Install six bell housing bolts. Tighten to 51-64 ft. lbs.
8. Lower vehicle.
9. Install RH and LH engine mount nuts and tighten to 95-125 ft lb.
10. Clean exhaust manifold and cylinder head gasket surface, then install new gaskets, RH and LH exhaust manifolds and manifold bolts. Tighten bolts to 26-32 ft lb.
11. Install oil level indicator tube.
12. Install RH and LH front fender aprons and pushpins.
13. Raise and support vehicle.
14. Install exhaust inlet pipe to exhaust manifold and tighten bolts to 26-33 ft. lbs.
15. Install lower radiator hose to oil cooler.
16. Install oil bypass filter. Tighten 1/2 turn after gasket contacts cylinder block or torque to 95-125 inch lbs.
17. Install shift cable to transmission.
18. Install torque converter nuts and tighten to 20-34 ft lb.
19. Connect LH heated oxygen sensor electrical connector.
20. Connect engine control sensor wiring to transmission.
21. Position transmission inspection shield to bell housing and install inspection shield bolts. Tighten to specifications.
22. Position starter motor to bell housing and install starter mounting bolts. Tighten to 17-20 ft. lbs.
23. Connect starter electrical connector.
24. Position starter cable to starter solenoid and install starter solenoid nut. Tighten to 7.5-10 ft lb.
25. Position transmission cooler line to engine bracket and install transmission cooler line to engine nut.
26. Install battery to starter relay cable into clips on front of engine.
27. Install ground cable onto front of engine.
28. Install power steering cooler to steering gear and tighten power steering cooler nuts to 50-68 ft lb.
29. Connect heater hoses to heater core.
30. Connect PCM, chassis wiring harness and ground cable electrical connectors.
31. Install accelerator cable bracket to throttle body.
32. Connect accelerator cable to throttle body.
33. Install throttle body snow shield and tighten to specifications.
34. Connect crankcase ventilation hose to throttle body.
35. Connect all vacuum lines.
36. Connect lower steering column shaft to steering gear and tighten lower steering column shaft bolt to specifications.
37. Connect emissions vapor management hose to intake manifold.
38. Connect fuel lines to connectors on inner fender.
39. Connect alternator electrical connectors.
40. Install ignition coil bracket with ignition coil and connect electrical connectors and EGR vacuum and electrical connectors.
41. Connect spark plug wires to spark plugs.
42. Position power steering pump and A/C compressor bracket to engine and install mounting bolts.
43. Connect A/C lines to A/C compressor.
44. Install power steering pump and tighten to specifications.
45. Install power steering reservoir.
46. Turn drive belt tensioner clockwise, install drive belt, then release tensioner.
47. Install battery, then battery hold-down bolt and battery heat shield.
48. Connect positive battery cable.
49. Install radiator and A/C condenser core.
50. Connect battery ground cable.
51. Charge A/C system and install hood.
52. Turn ignition switch to On position several times without starting engine to pressurize fuel system.
53. Start engine and check for leaks.
54. It will be necessary to drive vehicle to allow the PCM to relearn values for optimal driveability and performance.