Engine: Service and Repair

1. Disconnect battery ground cable, then drain cooling system.
2. Disconnect throttle, cruise control and TV cables.
3. Remove plenum extension from plenum.
4. Disconnect EGR pipe from intake and exhaust manifolds.
5. Remove ignition distributor from engine.
6. Disconnect electrical connector from oil pressure switch.
7. Disconnect windshield wiper motor electrical connector, then remove wiper motor cover.
8. Remove air intake duct.
9. Disconnect power brake unit vacuum hose.
10. Disconnect fuel vapor canister hoses.
11. Disconnect electrical connectors from cooling fan control switch, alternator, EGR solenoid, coolant temperature sensor, AIR switch and control valve, throttle position sensor, idle air control valve, A/C compressor and manifold air temperature sensor. Also disconnect fuel injector wiring harness from left and right hand sides.
12. Disconnect vapor hose from intake manifold. Also disconnect cruise control and A/C vacuum connectors.
13. Disconnect heater hose at throttle body.
14. Disconnect upper radiator hose at thermostat housing.
15. Remove water pump damper, then remove serpentine drive belt and water pump pulley.
16. Remove AIR switch, control and mounting bracket.
17. Relieve fuel system pressure as described under MAINTENANCE PROCEDURE/RELIEVING FUEL SYSTEM PRESSURE then disconnect and cap fuel lines at fuel rail.
18. Remove A/C accumulator clamping bolt.
19. Remove lower right hand side wheel housing center panel.
20. Remove A/C compressor brace, then remove A/C compressor and accumulator from mounting brackets and position aside with refrigerant hoses attached.
21. Remove A/C compressor front mounting brace, then remove belt tensioner.
22. Disconnect heater hose from water pump.
23. Remove A/C compressor lower brace and fuel line clamp.
24. Remove alternator, then remove AIR pump with mounting brackets and pipe as an assembly.
25. Remove A/C compressor mounting bracket and AIR system muffler.
26. Disconnect lower radiator hose from water pump, then disconnect hose from engine oil cooler pipe.
27. Remove crankshaft pulley.
28. Remove power steering pump with bracket and position aside with hoses attached.
29. Raise and support vehicle.
30. Disconnect AIR pipe from right hand exhaust manifold.
31. Disconnect exhaust cross-over pipe at exhaust manifolds.
32. Disconnect electrical connectors from oil temperature sensor, starter motor, ESC sensor and right hand side coolant temperature sensor. Also disconnect battery ground cable at engine block.
33. Remove flywheel cover, then remove starter motor.
34. Drain crankcase, then remove oil filter.
35. On models with manual transmission, remove transmission and clutch assembly.
36. On models with automatic transmission, remove transmission to engine and torque converter to flywheel attaching bolts.
37. On all models, remove engine mount through bolts and nuts.
38. Lower vehicle.
39. On models with automatic transmission, use suitable transmission jack to support transmission.
40. On all models, install suitable engine lifting fixture, then ensure all wiring and hoses that would interfere with engine removal are disconnected.
41. Carefully lift engine from vehicle.
42. Reverse procedure to install