Engine: Service and Repair

REMOVAL PROCEDURE





1. Remove the fuel pump fuse.
2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.
3. Remove the hood.
4. Drain the engine oil.
5. Disconnect the negative battery cable.
6. Discharge the air conditioning (A/C) system, if equipped. Refer to Heating and Air Conditioning.





7. Disconnect the Intake Air Temperature (IAT) sensor connector.
8. Remove the air intake tube.
9. Disconnect the breather tubes from the valve cover.
10. Remove the right front wheel.
11. Remove the right front wheel well splash shield.
12. Remove the serpentine accessory drive belt. Refer to Steering; Power Steering Pump.
13. Drain the engine coolant. Refer to Cooling System.
14. Remove the cooling system radiator and the engine cooling fans. Refer to Cooling System.
15. Disconnect the upper radiator hose from the thermostat housing.





16. Disconnect the power steering return hose from the power steering pump. Collect the oil in a suitable container.
17. Disconnect the power steering pressure hose from the power steering pump. Collect the oil in a suitable container.
18. Disconnect the electrical connector at the Electronic Ignition (EI) system ignition coil and the Engine Control Module (ECM) ground terminal.
19. Disconnect the oxygen sensor connector.





20. Disconnect the Idle Air Control (IAC) valve connector and the Manifold Absolute Pressure (MAP) sensor connector.
21. Disconnect the Throttle Position Sensor (TPS) connector.
22. Disconnect the Engine Coolant Temperature (ECT) sensor connector.
23. Disconnect the Coolant Temperature Sensor (CTS) connector.
24. Disconnect the generator voltage regulator connector and the power lead.
25. Disconnect the Camshaft Position (CMP) sensor connector.
26. Disconnect the vacuum lines, as needed, including the brake booster vacuum hose.
27. Disconnect the fuel return line at the fuel pressure regulator.





28. Disconnect the fuel feed line at the fuel rail.
29. Remove the fuel rail and the injector channel cover as an assembly. Refer to Powertrain Management.





30. Disconnect the throttle cable from the throttle body and the intake manifold bracket.
31. Disconnect the coolant hose at the throttle body.
32. Disconnect the heater outlet hose at the coolant pipe.
33. Disconnect the coolant bypass hose from the cylinder head.
34. Disconnect the surge tank coolant hose from the coolant pipe.
35. Disconnect the lower radiator hose from the coolant pipe.
36. Disconnect the starter solenoid "S" terminal wire and the power lead.
37. Remove the A/C compressor. Refer to Heating and Air Conditioning.





38. Remove the auxiliary catalytic converter lower flange nuts.





39. Remove the nuts that secure the front muffler pipe to the main catalytic converter.
40. Remove the rubber hangers that attach the connecting pipe to the vehicle.





41. Remove the connecting pipe mounting bracket nuts and the bracket.
42. Remove the main catalytic converter and the connecting pipe.





43. Remove the crankshaft pulley bolts.
44. Remove the crankshaft pulley.
45. Disconnect the vacuum lines at the Evaporative (EVAP) emission canister purge solenoid.
46. Disconnect the electrical connector at the EVAP canister purge solenoid.
47. Disconnect the electrical connector at the oil pressure switch.
48. Disconnect the Crankshaft Position (CKP) and the knock sensor connectors.
49. Support the transaxle with a floor jack.
50. Remove the center member. Refer to Transmission and Drivetrain.
51. Install the engine lifting device.





52. Remove the transaxle torque converter bolts from a vehicle with an automatic transaxle.
53. Remove the transaxle bell housing bolts and the oil pan flange bolts.
54. Remove the right engine mount bracket.
55. Remove the resonator bolts and the resonator.
56. Remove the air filter housing and the bolts.





57. Disconnect the right engine mount bracket from the engine mount and the engine by removing the retaining bolts.
58. Separate the engine block from the transaxle. Remove the engine.

INSTALLATION PROCEDURE
1. Install the engine into the engine compartment.
2. Align the engine alignment pins to the transaxle.





3. Install the transaxle bell housing bolts.
Tighten
Tighten the transaxle, bell housing bolts to 75 Nm (55 ft. lbs.).
4. Install the oil pan flange-to-transaxle retaining bolts.
Tighten
Tighten the oil pan flange-to-transaxle retaining bolts to 40 Nm (30 ft. lbs.).
5. Install the right engine mount bracket to the engine block mount and the frame mount.





6. Install the right engine mount bracket retaining bolts and the nuts.
Tighten
Tighten the engine mount bolts to 60 Nm (44 ft. lbs.).
7. Install the rear engine/transaxle mount bracket.
8. Install the center member. Refer to Steering and Suspension.
9. Remove the floor jack used for support of the transaxle.
10. Remove the engine lifting device.





11. Install the transaxle torque converter bolts on a vehicle with an automatic transaxle.
Tighten
Tighten the transaxle torque converter bolts to 60 Nm (44 ft. lbs.).
12. Connect the vacuum lines at the Evaporative (EVAP) emission canister purge solenoid.
13. Connect the electrical connectors to the EVAP emission canister purge solenoid.
14. Connect the oil pressure switch connector.
15. Install the crankshaft pulley.





16. Install the crankshaft pulley bolts.
Tighten
Tighten the crankshaft pulley bolts to 20 Nm (15 ft. lbs.) using a torque wrench.
17. Connect the Crankshaft Position (CKP) and the knock sensor connectors.





18. Insert the main catalytic converter bolts into the front muffler flange.
19. Install the rubber hangers that attach the connecting pipe to the vehicle.
20. Install the nuts to secure the front muffler pipe to the main catalytic converter.
Tighten
Tighten the front muffler pipe-to-main catalytic converter nuts to 30 Nm (22 ft. lbs.).





21. Install the auxiliary catalytic converter lower flange bolts.
Tighten
Tighten the auxiliary catalytic converter-to-connecting pipe nuts to 40 Nm (30 ft. lbs.).
22. Install the connecting pipe mounting bracket and nuts.
Tighten
Tighten the connecting pipe mounting bracket nuts to 30 Nm (22 ft. lbs.).





23. Connect the power steering pressure hose.
24. Connect the power steering return hose.
25. Install the A/C compressor, if equipped. Refer to Heating and Air Conditioning.
26. Install the serpentine accessory drive belt.
27. Install the right front wheel well splash shield.
28. Install the right front wheel.





29. Connect the fuel feed line to the fuel rail.
30. Connect the fuel return line to the fuel pressure regulator.
31. Install the fuel rail and the injector channel cover as an assembly. Refer to Powertrain Management.
32. Connect all the previously disconnected vacuum lines, including the brake booster vacuum hose.
33. Connect the oxygen sensor connector.
34. Connect the starter solenoid "S" terminal wire and the power lead.
35. Connect the generator voltage regulator connector.





36. Connect the Coolant Temperature Sensor (CTS) connector.
37. Connect the Engine Coolant Temperature (ECT) sensor connector.
38. Connect the Throttle Position Sensor (TPS) connector.
39. Connect the Idle Air Control (IAC) valve connector.
40. Connect the Manifold Absolute Pressure (MAP) sensor connector.
41. Connect the Camshaft Position (CMP) sensor connector.





42. Connect the electrical connector at the El system ignition coil and the Engine Control Module (ECM) ground terminal.
43. Install the air intake tube.
44. Install the air filter housing and the bolts.
Tighten
Tighten the air filter housing bolts to 8 Nm (71 inch lbs.).
45. Connect the breather tubes to the valve cover.
46. Connect the Intake Air Temperature (IAT) sensor connector.
47. Install the cooling system radiator and the engine cooling fans. Refer to Cooling System.
48. Install the resonator and the retaining bolts.
Tighten
Tighten the resonator retaining bolts to 8 Nm (71 inch lbs.).





49. Connect the lower radiator hose to the coolant pipe.
50. Connect the upper radiator hose to the thermostat housing.
51. Connect the heater inlet hose to the cylinder head.
52. Connect the heater outlet hose to the coolant pipe.
53. Connect the coolant surge tank hose to the coolant pipe.
54. Connect the coolant hose to the throttle body.





55. Connect the throttle cable to the throttle body and the intake manifold bracket.
56. Install the fuel pump fuse.
57. Connect the negative battery cable.
58. Refill the engine crankcase with engine oil.
59. Refill the engine coolant system. Refer to Cooling System.
60. Fill and bleed the power steering system. Refer to Steering.
61. Refill the A/C refrigerant system, if equipped. Refer to Heating and Air Conditioning.
62. Install the hood.