Removal and Replacement

REMOVAL
1. Place a protective cloth over the windshield frame. Raise the hood and rest it on the windshield frame.
2. Disconnect the battery negative cable.





Fig. 44

3. Remove the air cleaner resonator and related duct work. (Fig. 44)

WARNING: THE COOLANT IN A RECENTLY OPERATED ENGINE IS HOT AND PRESSURIZED. USE CARE TO PREVENT SCALDING BY HOT COOLANT. CAREFULLY RELEASE THE PRESSURE BEFORE REMOVING THE RADIATOR DRAIN COCK AND CAP.

4. Remove the radiator drain cock and radiator cap to drain the coolant. DO NOT waste usable coolant. If the solution is clean, drain the coolant into a clean container for reuse. Close drain cock when draining is complete.
5. Discharge A/C system and disconnect compressor suction/discharge hose assembly (if A/C equipped). Refer to Heating and Air Conditioning for correct procedures.
6. Remove upper radiator hose.
7. Remove the viscous fan/drive assembly.
8. Remove accessory drive belt.
9. Disconnect the transmission cooler lines (if equipped) from the radiator.
10. Disconnect lower radiator hose at radiator.
11. Remove the fan shroud screws.
12. Remove the radiator attaching bolts.
13. Remove the radiator and fan shroud.
14. Disconnect the wires at the starter motor solenoid.
15. Disconnect the wire connectors from the generator. Secure the harness out of the way.
16. If equipped with A/C, disconnect the compressor clutch connector and the A/C hi-pressure switch connector.
17. Disconnect the ignition coil and distributor wire connectors.
18. Disconnect the oil pressure sender wire connector.
19. Disconnect harness ground at the engine oil dipstick tube mounting stud. Secure the harness out of the way.
20. Disconnect the heater hoses from the thermostat housing and water pump inlet tube.
21. Disconnect CCV hoses from the cylinder head cover and intake manifold (Fig. 44).
22. Disconnect the accelerator, transmission line pressure (if equipped), and speed control (if equipped) cables from the throttle body.
23. Remove cable(s) from the bracket and secure out of the way.
24. Disconnect the body ground at the engine.
25. Disconnect the following connectors and secure their harness out of the way:
- Power steering pressure switch (if equipped)
- Coolant temperature sensor at the thermostat housing
- Four (4) fuel injector connectors
- Intake air temperature sensor
- Idle air control motor
- Throttle position sensor
- MAP sensor
- Crankshaft position sensor
- Oxygen sensor
26. Disconnect the CCV, HVAC supply, brake booster supply, and canister purge hoses from the intake manifold.
27. Relieve fuel pressure.
28. Disconnect the fuel supply line at the fuel rail.
29. If equipped with power steering:
a. Disconnect the hoses from the fittings at the steering gear.
b. Drain the pump reservoir.
c. Cap the fittings on the hoses and steering gear to prevent foreign objects from entering the system.
30. Lift the vehicle and support it with support stands.
31. Remove the oil filter.
32. Remove the starter motor.
33. Remove the engine support cushion-to-bracket through bolts.
34. Disconnect the exhaust pipe from the manifold.





Fig. 46

Manual Transmission models: (Fig. 46)
35. Remove two (2) clutch housing inspection cover bolts and the two (2) clutch housing inspection cover bolts/nuts.
36. Remove shield.
37. Remove six (6) clutch housing to engine block bolts.
Proceed to Step 41





Fig. 45

Automatic Transmission models: (Fig. 45)
38. Remove two (2) torque converter housing inspection cover bolts and the two (2) torque convertor housing inspection cover bolts/nuts.
39. Remove four (4) torque converter to flexplate bolts.
40. Remove six (6) transmission to engine block bolts.
41. Drain the engine oil.
42. Lower the vehicle.
43. Attach a lifting device to the engine.
44. Raise the engine off the front supports.
45. Place a floor jack or support stand under the flywheel/converter housing.
46. Separate the engine from the transmission, lift the engine out of the engine compartment and install on an engine stand.
47. Install the oil filter to keep foreign material out of the engine.

INSTALLATION
1. Remove the oil filter.
2. Lift the engine off the stand and lower it into the engine compartment. For easier installation, it may be useful to remove the engine support cushions from the engine support brackets as an aide for alignment of the engine-to-transmission.
Manual Transmission models: (Fig. 46)
3. Lower engine into compartment.
4. Insert the transmission shaft into the clutch spline.
5. Align the flywheel housing with the engine.
6. Install and tighten the flywheel housing bolts to 38 Nm (28 ft. lbs.).
Proceed to Step 10
Automatic Transmission models: (Fig. 45)
7. Align converter housing with engine.
8. Install and tighten the converter housing bolts to 38 Nm (28 ft. lbs.).
9. Install and tighten the torque converter to flexplate bolts to 68 Nm (50 ft. lbs.).
10. Remove the floor jack or support stand from beneath the flywheel/converter housing.
11. Lower the engine and engine support cushions onto the engine compartment brackets. Ensure that the bolt holes are aligned. Install the thru-bolts and nuts and tighten to 81 Nm (60 ft. lbs.).
12. Remove the engine lifting device.
13. Raise the vehicle.
14. Install inspection cover and tighten bolts/nuts to 16 Nm (138 in. lbs.).
15. Attach the exhaust pipe to the manifold. Install and tighten the nuts to 31 Nm (23 ft. lbs.) torque.
16. Install the starter motor and bolts. Tighten the bolts to 45 Nm (33 ft. lbs.).
17. Install the oil filter.
18. Lower the vehicle.
19. If equipped with power steering:
a. Remove the protective caps
b. Connect the hoses to the fittings at the steering gear. Tighten the nut to 52 Nm (38 ft. lbs.) torque.
c. Fill the pump reservoir with fluid.
20. Inspect the fuel supply line O-rings and replace if necessary. Install fuel supply line to fuel rail. Push until a "click" is heard. Verify the connection by pulling outward on line. Install latch clip.
21. Attach fuel supply line bracket to intake manifold.
22. Connect the brake booster, HVAC, canister purge, and CCV vacuum hoses to the intake manifold.
23. Connect the following electrical connectors:
- Power steering pressure switch (if equipped)
- Coolant temperature sensor at the thermostat housing
- Four (4) fuel injector connectors
- Intake air temperature sensor
- Idle air control motor
- Throttle position sensor
- MAP sensor
- Crankshaft position sensor
- Oxygen sensor
24. Install the engine ground strap.
25. Connect heater hoses to thermostat housing and water pump inlet tube.
26. Connect accelerator cable, transmission line pressure cable (if equipped), and speed control cable (if equipped) to bracket and throttle body.
27. Install the fan shroud and radiator. Tighten fan shroud and radiator fasteners to 8 Nm (75 in. lbs.).
28. Connect transmission cooler lines (if equipped). Tighten fittings to 15 Nm (135 in. lbs.).
29. Install the viscous fan/drive assembly. Tighten nuts to 27 Nm (20 ft. lbs.).
30. Install and tension the accessory drive belt.
31. Install the radiator hoses.
32. Connect the following electrical connectors:
- Ignition coil
- Distributor
- Starter motor
- A/C compressor clutch (if equipped)
- A/C Hi-pressure switch (if equipped)
- Generator
- Oil pressure sender
- Harness ground at dipstick tube bracket
33. Remove the coolant temperature sending unit to permit air to escape from the block. Fill the cooling system with coolant. Install the coolant temperature sending unit when the system is filled.
34. Connect A/C suction/discharge hose and recharge A/C system. Refer to Heating and Air Conditioning for correct procedures.
35. Install air cleaner resonator and duct work.
36. Lower the hood and secure in place.
37. Start the engine and inspect for leaks.
38. Stop the engine and check all fluid levels. Add fluid, as required.