Removal & Installation: Engine: Removal
- Disconnect battery ground cable. Disconnect ground strap near right hood hinge. Mark hood-to-hinge location and remove hood. Depressurize EFI fuel system by connecting vacuum pump to fuel pressure regulator valve. Apply a minimum of 25 in. Hg for at least 3 minutes.NOTE: It is recommended to mark electrical connectors and vacuum hoses, to ensure correct reassembly.
- Remove cooling system expansion tank cap and drain radiator. Disconnect radiator upper hose at radiator. On manual transmission, also remove air vent hose at radiator. Remove radiator upper attaching bolts. Disconnect cooling fan wiring connector. Remove oil dipstick.
- Remove vacuum hose from EGR valve. Disconnect fuel injection wiring harness connector. Remove remaining electrical connectors. See Fig 1.
- Using Quick Connect Remover/Replacer (T82L-9500-AH), disconnect fuel return line. Disconnect throttle cable and transmission kickdown cable (if equipped). Remove throttle cable bracket. Disconnect vacuum supply hose from vacuum tee, located by master cylinder.
- Remove alternator from mounting bracket and secure out of way. Remove power steering pump and secure out of way. Remove turbocharger inlet tube. Disconnect Orange ground wire at turbocharger inlet elbow. Disconnect vacuum hose at tee located at turbocharger inlet elbow.
- Remove A/C compressor from its mounting and secure out of way. On automatic transmission models, remove transmission dipstick tube attaching nut at turbocharger outlet flange. Disconnect coolant supply and return hoses at heater control valve.
- Remove transmission cooler lines at radiator (if equipped). Raise vehicle. On manual transmission models, remove radiator refill tube, located at bottom of radiator.
- Remove lower radiator hose. Remove radiator retaining bolts and remove radiator out bottom of vehicle. Remove chassis ground strap from A/C compressor bracket. Remove starter. Remove nuts attaching catalytic converter inlet pipe to turbocharger.
- Remove inlet pipe-to-catalytic converter bolts. Remove support bracket bolt and remove inlet pipe. On manual transmission models, remove bolt retaining rear engine cover to flywheel housing.
- Rotate crankshaft (clockwise only), and remove flexplate-to-torque converter bolts through starter housing. Remove nut retaining engine mount to crossmember. Remove bolts retaining transmission to engine. Upper bolts may be loose and left in transmission housing if removal is prevented.
- If necessary to gain access to bolts, support transmission on jack and remove mount nuts securing transmission. Remove nuts securing drive shaft center bearing support. Lower transmission for bolt access. With bolts removed, reinstall transmission and drive shaft. Lower vehicle.
- Attach engine hoist to engine at left front and right rear. Support transmission with a jack. Raise engine until engine mounts clear crossmember. Remove engine mount assemblies from engine. Pull engine away from transmission and remove engine.