Engine

REMOVAL & INSTALLATION

In the process of removing the engine, you will come across a number of steps which call for the removal of a separate component or system, such as "disconnect the exhaust system'' or "remove the radiator.'' In most instances, a detailed removal procedure can be found elsewhere in this manual.

It is virtually impossible to list each individual wire and hose which must be disconnected, simply because so many different model and engine combinations have been manufactured. Careful observation and common sense are the best possible approaches to any repair procedure.

Removal and installation of the engine can be made easier if you follow these basic points:

• If you have to drain any of the fluids, use a suitable container.
• Always tag any wires or hoses and, if possible, the components they came from before disconnecting them.
• Because there are so many bolts and fasteners involved, store and label the retainers from components separately in muffin pans, jars or coffee cans. This will prevent confusion during installation.
• After unbolting the transmission, always make sure it is properly supported.
• If it is necessary to disconnect the air conditioning system, have this service performed by a qualified technician using a recovery/recycling station. If the system does not have to be disconnected, unbolt the compressor and set it aside.
• When unbolting the engine mounts, always make sure the engine is properly supported. When removing the engine, make sure that any lifting devices are properly attached to the engine. It is recommended that if your engine is supplied with lifting hooks, your lifting apparatus be attached to them.
• Lift the engine from its compartment slowly, checking that no hoses, wires or other components are still connected.
• After the engine is clear of the compartment, place it on an engine stand or workbench.
• After the engine has been removed, you can perform a partial or full teardown of the engine using the procedures outlined in this manual.

CAUTION
Fuel injection systems remain under pressure after the engine has been turned

OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

1. Disconnect the negative battery cable. Wait at least 90 seconds to proceed working on the vehicle if equipped with an airbag.

   CAUTION
   Some models covered by this manual may be equipped with a Supplemental Restraint System (SRS), which uses an air bag. Whenever working near any of the SRS components, such as the impact sensors, the air bag module, steering column and instrument panel, disable the SRS, as described in Section 6.

2. Drain the engine coolant and oil.
3. Relieve the fuel system pressure.
4. Raise the vehicle and support safely. Remove the engine under covers.
5. Drain the engine oil and cooling system.
6. On 4WD vehicles, disconnect the front driveshaft.
7. Remove the rear driveshaft.
8. Remove the air duct.
9. Matchmark and disconnect the equipment (separated accessory drive system) driveshaft from the crankshaft pulley.
10. Disconnect the A/T shift cable.
11. Remove the air intake duct.
12. Disconnect the ground strap from the left hand front engine mounting.
13. Disconnect the starter wire.
14. Disconnect the following hoses:
    • No. 4 radiator hose from the water inlet
    • No. 1 radiator hose from the water inlet
    • Heater hose from the water pump
    • Oil auto feeder hose from the No. 1 oil return pipe
    • Disconnect the A/C idle up air hose from the union under the intake manifold
    • Disconnect the power steering idle up air hose from the union under the intake manifold
    • Disconnect the water bypass hose from the floor pipe
    • Disconnect the brake booster hose from the floor pipe
    • Disconnect the two vacuum hoses for the fuel pressure control Vacuum Switching Valve (VSV) from the engine wire and vacuum transmitting pipe on the throttle body
    • Air hose for the distributor ventilation from the water bypass pipe under the intake manifold
    • Disconnect the vacuum hose for the EVAP from the charcoal canister
15. If equipped with automatic transmission, disconnect the shift cable.
16. Remove the intake pipe hose.
17. Disconnect the accelerator cable from the throttle body.
18. Disengage the Vacuum Switching Valve (VSV) connector for the fuel pressure control.
19. Disconnect the engine wire from the engine left side as follows:
    1. Disengauge the igniter connector.
    2. Disconnect the two Electronic Control Module (ECM) harnesses.
    3. Disconnect the four harnesses from the cowl wire on the front floor panel.
    4. Separate the engine wire from the front floor panel by removing the bolt and detaching the three clamps.
    5. Pull out the engine wire from the front floor panel hose.
20. Remove the A/T oil dipstick.
21. Disconnect the fuel inlet and return hoses.
22. Remove the front exhaust pipe.
23. Remove the exhaust pipe heat insulator and ground strap by removing the four bolts.
24. Disconnect the two A/T oil cooler hoses.
25. Remove the ignition coil and disconnect the ground strap for the engine.
26. Disconnect the condenser wiring.
27. Disconnect the four clamps and engine wire.
28. Disconnect the A/T and park/neutral position switch wiring.
29. Remove the engine with the transmission as follows:
    1. Support the engine and transmission with a supporting device.
    2. Lower the vehicle while supporting the engine and transmission with the engine lifter.
    3. Remove the two bolts, two nuts and two plate washers holding the right and left engine mountings to the engine front support member.
    4. Remove the four through bolts, four plate washers and four nuts holding the rear mounting to the No. 2 rear engine mounting bracket.
    5. Make sure the engine and transmission are clear of all wiring, hoses and cables.
    6. Lower the engine and transmission to the floor.
30. Install the engine in the reverse order of removal while paying close attention to the following.
31. Raise the engine and install the two bolts, two plate washers and two nuts to hold the right and left engine front mountings to the engine front support member. Tighten the bolts and nuts to 27 ft. lbs. (37 Nm).
32. Install the two through bolts, four washers and four nuts to hold the engine rear mounting to the No. 2 rear engine mounting bracket. Tighten the bolts and nuts to 31 ft. lbs. (42 Nm).
33. Install the rear driveshaft. If equipped with 4WD, install the front driveshaft. Install a new oil filter and fill the engine with oil. Fill the engine with engine coolant. Install the engine undercovers. Start the engine and check for leaks.