Engine: Service and Repair
RemovalSpecial Tools Required
Front subframe adapter
NOTE:
^ Use fender covers to avoid damaging painted surfaces.
^ To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
^ Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring or hoses, or interfere with other parts.
1. Secure the hood in the wide open position (support rod in the lower hole).
2. Make sure you have the anti-theft code for the radio, then write down the frequencies for the radio's preset buttons.
3. Disconnect the negative cable from the battery first, then disconnect the positive cable.
4. Remove the battery.
5. Remove the intake manifold cover.
6. Disconnect the intake air temperature (IAT) sensor connector (A), remove the breather hose (B) and vacuum hose (C), then remove the air cleaner housing cover/intake air duct assembly (D).
7. Remove the air cleaner housing.
8. Remove the intake air duct.
9. Remove the battery cables (A) from the under-hood fuse/relay box, then remove the harness clamp (B) and ground cable (C).
10. Fully open the throttle link and cruise control link by hand, then remove the throttle cable (A) and cruise control cable (B) from the links. Loosen the locknuts (C), and remove the cables from the bracket.
11. Relieve fuel pressure.
12. Remove the fuel line).
13. Remove the evaporative emission (EVAP) canister hose (A) and brake booster vacuum hose (B).
14. Remove the clutch slave cylinder (A) and clutch line bracket mounting bolt (B).
15. Remove the shift cable (A) and select cable (B).
16. Disconnect the engine control module (ECM) connectors (A) and main wire harness connector
17. Remove the harness clamps (A) and grommet (B), then pull the engine wire harness through the bulkhead.
18. Remove the drive belt.
19. Remove the A/C line mounting bolt.
20. Remove the radiator cap.
21. Raise the hoist to full height.
22. Remove the front tires/wheels.
23. Remove the splash shield.
24. Loosen the drain plug in the radiator to drain the engine coolant.
25. Drain the transmission fluid.
26. Drain the engine oil.
27. Disconnect the stabilizer links.
28. Disconnect the suspension lower arm ball joints.
29. Remove the driveshafts. Coat all precision finished surfaces with clean engine oil. Tie plastic bags over the driveshaft ends.
30. Disconnect the air fuel ratio (A/F) sensor connector (A) and secondary heated oxygen sensor (secondary HO2S) connector (B), then remove the three way catalytic converter (TWC) assembly (C).
31. Remove the lower hose.
32. Lower the hoist.
33. Remove the upper hose (A) and heater hoses (B).
34. Remove the radiator.
35. Attach the chain hoist to the engine as shown.
36. Remove the transmission mount bracket support bolt and nuts.
37. Remove the upper bracket mounting bolt and nut.
38. Make sure the hoist brackets are positioned properly. Raise the hoist to full height.
39. Remove the rear mount mounting bolts.
40. Remove the front mount bracket mounting bolt.
41. Attach the subframe adapter to front of the subframe, then tighten the knurled knob.
42. Raise the jack. Line up the slots in the arms with the bolt holes on the corner of the jack base, then attach the adapter to the jack base with the bolts.
43. Use a marker to make alignment marks on the reference lines (A) that align with the centers of the rear subframe mounting bolts (B).
44. Remove the front subframe (C).
45. Disconnect the compressor clutch connector (A), then remove the A/C compressor (B) without disconnecting the A/C hoses.
46. Check that the engine/transmission is completely free of vacuum hoses, fuel and coolant hoses, and electrical wiring.
47. Slowly lower the engine about 150 mm (6 inch). Check once again that all hoses and wires are disconnected from the engine/transmission.
48. Lower the engine all the way. Remove the chain hoist from the engine.
49. Remove the engine from under the vehicle.
Installation
Special Tools Required
Front subframe adapter
1. Install the accessory brackets, and tighten their bolts and nuts to the specified torques.
2. Position the engine under the vehicle. Attach the chain hoist to the engine, then lift the engine into position in the vehicle.
NOTICE: Reinstall the mounting bolts/support nuts in the sequence given. Failure to follow this sequence may cause excessive noise and vibration, and reduce bushing life.
3. Install the A/C compressor (A), and connect the compressor clutch connector (B).
4. Support the subframe with the subframe adapter and a jack.
5. Install the subframe (A). Align the reference marks (B) on the subframe with the center of the bolt heads, then tighten the bolts.
6. Tighten the rear mount mounting bolts.
7. Loosely tighten the front mount bracket mounting bolt.
8. Lower the hoist.
9. Tighten the upper bracket mounting bolt and nut.
10. Tighten the transmission mount bracket support bolt and nuts.
11. Raise the hoist to full height.
12. Tighten the front engine mount bracket mounting bolt.
13. Lower the hoist.
14. Remove the chain hoist from the engine.
15. Install the radiator.
16. Raise the hoist to full height.
17. Install a new set ring on the end of each driveshaft, then install the driveshafts. Make sure each ring "clicks" into place in the differential and intermediate shaft.
18. Connect the suspension lower arm ball joints.
19. Connect the stabilizer links.
20. Install the three way catalytic converter (TWC) assembly (A); use new gaskets (B) and new self locking nuts (C).
21. Connect the air fuel ratio (A/F) sensor connector (D) and secondary heated oxygen sensor (secondary HO2S) connector (E).
22. Install the lower radiator hose.
23. Install the splash shield.
24. Lower the hoist.
25. Install the drive belt.
26. Install the A/C line mounting bolt.
27. Install the upper radiator hose (A) and heater hoses (B).
28. Push the engine control module (ECM) connectors through the bulkhead, then install the grommet (A).
29. Install the harness clamps (B).
30. Connect the ECM connectors (A) and main wire harness connector (B).
31. Install the throttle cable, then adjust the cable.
32. Install the cruise control cable, then adjust the cable.
33. Install the brake booster vacuum hose (A) and the evaporative emission (EVAP) canister hose (B).
34. Install the fuel line.
35. Install the select cable (A) and shift cable (B) using the plastic washers (C), washers (D), and new cotter pins (E).
36. Install the clutch slave cylinder (A) and clutch line bracket mounting bolt (B).
37. Install the battery cables (A) on the under-hood fuse/relay box, then install the harness clamp (B).
38. Install the ground cable (C).
39. Install the intake air duct.
40. Install the air cleaner housing.
41. Install the air cleaner housing cover (A) and connect the intake air temperature (IAT) sensor connector (B).
42. Install the breather hose (C) and vacuum hose (D).
43. Install the intake manifold cover.
44. Install the battery. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion.
45. Check that the transmission shifts into gear smoothly.
46. Inspect for fuel leaks. Turn the ignition switch ON (II) (do not operate the starter) so that the fuel pump runs for about 2 seconds and pressurizes the fuel line. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
47. Refill the engine with engine oil.
48. Refill the transmission with fluid.
49. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
50. Perform the engine control module (ECM) idle learn procedure.
51. Inspect the idle speed.
52. Inspect the ignition timing.
53. Check the wheel alignment.
54. Enter the anti-theft code for the radio, then enter the customer's radio station presets.
55. Set the clock.