Engine: Service and Repair

REMOVAL
1. Disconnect battery ground cable.
2. Drain engine cooling system.
3. Recover A/C refrigerant from A/C system
4. Remove cowl top vent panel.
5. Disconnect alternator wiring connectors.
6. Loosen air cleaner outlet tube clamp at throttle body.
7. Disconnect upper radiator hose at radiator and secure to engine.
8. Disconnect heater water hoses and secure to body.
9. Remove A/C discharge at condenser and suction hoses at suction accumulator/drier and secure to engine.
10. Disconnect accelerator cable and speed control actuator cable from throttle body lever, then remove accelerator cable bracket from throttle body.
11. Position accelerator cable bracket with accelerator cable and speed control actuator cable out of way.
12. Disconnect fuel supply and return lines from fuel injection supply manifold.
13. Disconnect engine to body ground at RH cylinder head, fuel charging wiring from powertrain control module at upper RH rear corner of engine compartment and A/C high pressure sensor and low pressure sensor connectors at A/C suction accumulator/drier.
14. Disconnect power brake booster harness connector.
15. Disconnect harness connector to transaxle LH side of engine compartment, behind engine air cleaner.
16. Mark and disconnect vacuum hoses, heater and aspirator hose from vacuum tree and evaporative emission hose from throttle body.
17. Remove gear shift cable from transaxle.
18. Lock steering wheel with wheels in straight ahead position by turning ignition switch to Off position.
19. Raise and support vehicle.
20. Remove front wheel and tire assemblies.
21. Drain engine oil.
22. Disconnect transmission fluid cooler lines at transaxle and secure to radiator support.
23. Disconnect heated oxygen sensor wiring connectors.
24. Remove dual converter Y-pipe retaining bolts at pipe outlet and flex joint and install flex joint exhaust connector holder tool No. T94T-6000-AH or equivalent.
25. Remove nuts securing dual converter Y-pipe to exhaust manifolds and hanger bolt.
26. Remove dual converter Y-pipe.
27. Disconnect starter motor wires and secure out of way.
28. Remove starter motor.
29. Remove engine rear plate and torque converter to flywheel retaining nuts.
30. Remove nut retaining battery cable support bracket to upper starter motor mounting stud bolt.
31. Disconnect power steering cooler lines.
32. Disconnect lower radiator hose at radiator.
33. Remove heater water hoses to auxiliary heater, if equipped.
34. Remove upper bolt from sway bar links.
35. Remove dust boot from steering rack pinion support by gently spreading the integral tension ring and pushing upward.
36. Remove steering coupling pinch bolt from steering column intermediate shaft at steering gear.
37. Remove intermediate shaft at steering gear.
38. Remove RH and LH front stabilizer bar links from front stabilizer bar.
39. Separate RH and LH front suspension lower arms from front wheel knuckle at ball joint.
40. Separate RH and LH front axle wheel hub retainers from halfshaft ends.
41. Remove RH and LH halfshaft ends from front wheel knuckle.
42. Support front sub-frame, engine and transaxle assembly using powertrain lift tool and adapter tool Nos. 014-00765 and 014-00341 or equivalents.
43. Remove four front sub-frame retaining bolts.
44. Lower engine, transaxle and front sub-frame from vehicle.
45. Disconnect power steering pressure hose from power steering pump.
46. Install engine lifting eyes, tool No. D81L-6001-D or equivalent.
47. Connect engine lifting spreader bar from engine lift bracket set No. 014-00340 or equivalent, to lifting eyes. Support engine and transaxle.
48. Remove LH front engine support insulator, RH front engine support insulator and engine and transmission support.
49. Lift engine and transaxle from front sub-frame.
50. Lower engine and transaxle.
51. Support transaxle on level, stationary surface for transaxle storage.
52. Remove transaxle to cylinder block mounting bolts and separate engine from transaxle/torque converter assembly.
53. Place engine on suitable work stand.
54. Remove engine lifting equipment.
55. Remove water jacket pipe plugs in cylinder block and drain remaining engine coolant. Reinstall plugs.

INSTALLATION

1. Install engine lifting eyes, tool No. D81L-6001-D or equivalent.
2. Remove engine from stand using spreader bar and chains from engine lift bracket set, tool No. 014-00340 or equivalent.
3. Install transaxle/torque converter assembly to engine. Tighten transaxle to engine bolts and torque converter nuts to specifications.
4. Position engine and transaxle assembly on front sub-frame.
5. Install LH front engine support insulator, RH front engine support insulator and engine and transaxle support.
6. Connect power steering pressure hose to power steering pump.
7. Raise engine, transaxle and front sub-frame into position.
8. Align front sub-frame to body and install front sub-frame to body bolts. Tighten to specifications.
9. Remove powertrain lift equipment.
10. Partially lower vehicle.
11. Install RH and LH halfshaft into front wheel knuckle.
12. Install RH and LH front axle wheel hub retainers onto halfshaft end.
13. Connect RH and LH tie rod ends to front wheel knuckle.
14. Connect RH and LH front suspension lower arms to front wheel knuckle at ball joints.
15. Install RH and LH front stabilizer bar links to front stabilizer bar.
16. Install front wheel and tires.
17. Connect intermediate shaft to pinion gear of steering gear. Install pinch bolt and nut and tighten to specifications.
18. Install dust boot on pinion support of steering gear. Gently squeeze integral tension ring and slide dust boot on pinion support housing.
19. Install lower radiator hose and heater water hoses to auxiliary heater.
20. Install power steering fluid cooler lines.
21. Install dual converter Y-pipe to exhaust manifold and tighten to specifications.
22. Remove flex pipe support tool and connect dual converter Y-pipe and flex pipe. Tighten to specifications.
23. Connect wire harness to heated oxygen sensors.
24. Lower vehicle.
25. Remove engine lifting eyes from engine.
26. Install accelerator cable and speed control actuator cable to throttle body lever and accelerator cable bracket to throttle body. Tighten accelerator cable bracket bolts to specifications.
27. Install upper radiator hose to radiator.
28. Install heater water hoses.
29. Install vacuum hoses at vacuum tree and evaporative emission hose to throttle body.
30. Install gearshift cable to transaxle.
31. Connect engine to body ground at A/C suction accumulator bracket.
32. Connect fuel charging wiring to PCM.
33. Connect A/C high pressure sensor and low pressure sensor connectors at suction accumulator/drier.
34. Connect wiring harness connector to transaxle LH side of engine compartment and behind engine air cleaner.
35. Connect A/C discharge and suction hoses at suction accumulator/drier.
36. Connect supply and return fuel lines to fuel injection supply manifold.
37. Connect alternator electrical connector.
38. Install engine air cleaner and air cleaner outlet tube.
39. Replace oil bypass filter.
40. Fill crankcase to proper lever with suitable engine oil.
41. Fill engine cooling system.
42. Start engine and check for leaks.
43. Evacuate and recharge air conditioning system.
44. Install cowl top vent panel.
45. Check front end alignment.