Removal and Replacement

REMOVAL - ENGINE ASSEMBLY





1. Remove hood.
2. Release fuel pressure.
3. Disconnect negative battery cable (1) located in the trunk.





4. Disconnect intake air temperature sensor electrical connector.
5. Remove air cleaner housing assembly (3).





6. Remove accessory drive belt (5).
7. Disconnect lines from power steering pump (3).
8. Remove power steering pump attaching bolts and set pump aside (3).
9. Recover A/C system using a suitable refrigerant recovery machine.
10. Disconnect A/C compressor (4) electrical connectors.
11. Remove A/C compressor (4).





12. Raise vehicle.
13. Remove lower splash shield bolts (1) and remove splash shield (2).
14. Drain cooling system.





15. Drain the engine oil (5) and remove the oil filter (3).
16. Disconnect down stream oxygen sensor connectors.
17. Disconnect exhaust pipes at the manifolds.





18. Disconnect starter (2) electrical connectors.
19. Remove starter (2) bolts and set starter aside.





20. Disconnect coolant pipe (1) near starter from hose.
21. Disconnect crankshaft position sensor electrical connector and remove sensor.
22. Disconnect ground strap.





23. Disconnect oil pressure sensor (1) electrical connector.





24. Remove 4 engine mount nuts (1).
25. Remove engine mount studs (1) from mount.





26. Remove steering gear mounting bolts (1) and lower steering gear (2) for clearance.





27. Using a block of wood and a suitable lifting device under the oil pan, raise the engine.
28. Remove structural collar bolts (2 & 4).
29. Remove structural collar (3).
30. Remove lower bell housing bolts.
31. Lower engine and remove jack stand.
32. Mark flex plate to torque converter location.
33. Remove torque converter bolts.
34. Lower vehicle.





35. Remove wiper arms.
36. Remove wiper cowl (1).
37. Remove strut tower support (2).





38. Reposition purge solenoid (5).





39. Remove the intake manifold (2).
40. Disconnect all vacuum lines and electrical connectors.
41. Disconnect all ground straps attaching to the engine.





42. Disconnect fuel line at fuel rail (1).
43. Disconnect coil, injector (2), capacitor, and knock sensor connectors.
44. Remove EGR valve and tube assembly.





45. Remove upper bellhousing bolts and reposition electrical harness.
46. Attach special tool #8342A (1).
a. Attach special tool #8342A to the front of the left cylinder head (2).
b. Attach special tool #8342A to the rear of the right cylinder head (3).
47. Support transmission with a block of wood and floor jack.
48. Hoist engine from engine compartment.

INSTALLATION - ENGINE ASSEMBLY





1. Attach special tool #8342A engine lifting fixture (1). a. Attach special tool #8342A to the front of the left cylinder head (2). b. Attach special tool #8342A to the rear of the right cylinder head (3).
2. Lower engine into engine compartment.
3. Remove special tool #8342A (1).

CAUTION: Do not tighten the transmission case to engine block bolts until all bolts have been hand started, and the two mating surfaces are completely joined together, as damage to cylinder block or transmission could occur.

4. Install bell housing to cylinder block bolts and tighten to 68 Nm (50 ft. lbs.).
5. Install EGR valve and tube assembly.





6. Connect coil, injector (2), capacitor, and knock sensor connectors.
7. Connect the fuel line (1).
8. Install upper intake manifold.





9. Install purge solenoid (5).
10. Connect all ground straps.
11. Connect all vacuum lines and electrical connectors.





12. Raise vehicle.
13. Align flexplate and torque converter.

NOTE: Make sure all four bolts are installed finger tight before torquing bolts.

14. Tighten torque converter bolts to 75 Nm (55 ft. lbs.).
15. Using a block of wood and a suitable lifting device under the oil pan, raise the engine.
16. Install the structural collar (3) and position in place.

NOTE: Make sure that structural collar (3) is flush with the oil pan (1) and the transmission bell housing.

17. Finger tighten all bolts (2 & 4).
18. Tighten the structural collar to oil pan bolts (2) to 55 Nm (40 ft. lbs.).
19. Tighten structural collar to transmission bolts (4) to 55 Nm (40 ft. lbs.).





20. Install the power steering pump (3).
21. Install the A/C compressor (4).





22. Install the crankshaft position sensor and connect electrical connector.
23. Connect oil pressure sensor (1) electrical connector.





24. Install starter (2), tighten bolts to 41 Nm (30 ft. lbs.).
25. Connect electrical connectors at starter.





26. Connect the coolant pipe (1) to coolant hose.
27. Connect the exhaust pipes to the manifolds.
28. Connect the down stream oxygen sensor connectors.
29. Connect A/C compressor electrical connectors.





30. Install new oil filter (3).





31. Install lower splash shield (2) and tighten retaining bolts (1).
32. Lower vehicle.





33. Install power steering pump (3).
34. Connect lines to power steering pump (3).
35. Install accessory drive belt (5).





36. Install air cleaner housing assembly (3).
37. Connect intake air temperature sensor connector.





38. Connect negative battery (1) cable.





39. Fill coolant system.
40. Fill engine with correct grade of oil (5).
41. Install strut tower support (2).
42. Install cowl screen (1).
43. Install wiper arms.
44. Install the hood.





45. Fill and bleed power steering system.
46. Evacuate and charge A/C system.
47. Start engine and check for leaks.