Removal and Replacement
REMOVAL - ENGINE ASSEMBLYNOTE: The engine and transmission is removed as an assembly.
1. Perform fuel pressure release procedure.
2. Disconnect battery.
3. Remove hood.
4. Remove hood hinges.
5. Disconnect throttle body air inlet hoses, remove air cleaner housing assembly.
6. Drain cooling system.
7. Discharge air conditioning system using a suitable refrigerant recovery machine.
8. Remove upper radiator hose and heater hoses from the engine.
9. Remove front crossmember (Fig. 5).
10. Remove accessory drive belt.
11. Remove power steering pump mounting bolts and set pump aside.
12. Disconnect engine electrical connectors and ground cable to the frame.
13. Remove lower radiator hose.
14. Remove windshield wiper arms.
15. Remove cowl cover.
16. Disconnect battery feed connector and brake booster vacuum hose.
17. Disconnect vacuum lines, evaporative emission harness, fuel lines and accelerator cable.
18. Raise vehicle on hoist.
19. Remove under body stone shield.
20. Disconnect exhaust system at left and right exhaust manifolds.
21. Remove starter and support with suitable strap.
22. Disconnect air conditioning lines from air conditioning compressor.
23. Disconnect oil cooler lines.
24. Remove drive shaft and disconnect torque bar from transmission.
25. Using Special Tool 6638, disconnect hydraulic clutch line quick connector at the transmission bell housing.
26. Disconnect transmission electrical connectors.
27. Using a crow-foot wrench, unscrew the isolator/shifter handle from the shifter tower.
28. Support transmission with suitable jack.
29. Remove transmission mount with crossmember (Fig. 6).
30. Remove left and right engine mount nuts (Fig. 6).
31. Lower vehicle.
32. Install suitable engine lifting brackets/chain. Remove engine and transmission as an assembly with an engine hoist.
INSTALLATION - ENGINE ASSEMBLY
1. Attach engine hoist and lower the engine and transmission into engine compartment.
2. Align left and right engine mounts and install mounting nuts (Fig. 6). Tighten nuts to 102 Nm (75 ft. lbs.).
3. Remove engine hoist and engine lifting brackets/chain.
4. Raise vehicle on hoist.
5. Install transmission mount with crossmember (Fig. 6).
6. Install transmission isolator/shifter handle to shifter tower.
7. Connect transmission electrical connectors
8. Connect hydraulic clutch line.
9. Install drive shaft and connect torque bar to transmission.
10. Connect oil cooler lines.
11. Connect air conditioning lines to air conditioning compressor.
12. Install starter.
13. Connect exhaust system at left and right exhaust manifolds using NEW V-Band clamps. Tighten V-Band clamps to 11 Nm (100 in. lbs.).
14. Install under body stone shield.
15. Lower vehicle.
16. Connect all vacuum lines.
17. Connect all electrical connections and ground strap.
18. Connect fuel lines and accelerator cable.
19. Install radiator hoses and connect heater hoses.
20. Install power steering pump.
21. Install accessory drive belt.
22. Install front crossmember (Fig. 5).
23. Install cowl cover.
24. Install windshield wiper arms.
25. Evacuate and recharge air conditioning system.
26. Fill cooling system.
27. Fill engine crankcase with proper oil to correct level.
28. Install air cleaner housing assembly, connect throttle body air inlet hoses.
29. Install hood hinges.
30. Install hood.
32. Start engine and run until operating temperature is reached.