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ENGINE 2.4L DOHC (Continued)
(33) Disconnect all ground straps attaching to
engine.
(34) Disconnect brake booster and vapor purge
vacuum hoses.
(35) Disconnect fuel line from fuel rail.
(36) Disconnect generator connectors.
(37) Remove
intake
ENGINE/MANIFOLDS/INTAKE
REMOVAL).
(38) Remove generator.
(39) Remove A/C suction line at compressor. Cap
suction port and line.
(40) Remove A/C compressor.
(41) Raise vehicle enough to allow engine dolly
6135 and cradle 6710 with posts 6848 to be installed
under vehicle (Fig. 6).
(42) Loosen cradle engine mounts to allow move-
ment for positioning onto engine locating holes on the
engine bedplate, compressor and support bracket.
Install adapters 6909 to the two post at rear of
engine. Lower vehicle and position cradle mounts
until the engine is resting on posts. Tighten post
mounts to cradle frame. This will keep mounts from
moving when removing or installing engine/transmis-
sion assembly. Secure engine/transmission to dolly/
cradle with safety straps.
(43) Lower vehicle so weight of the engine and
transmission ONLY is on the cradle.
(44) Remove right and left side vertical engine
mount bolts.
(45) Slowly raise vehicle in short length spans.
Inspect at each interval for potential engine or transaxle
contact to vehicle components. Move the cradle/dolly fix-
ture as necessary to allow for removal clearance.
INSTALLATION - ENGINE ASSEMBLY
(1) Position engine/transaxle assembly under vehicle
and slowly lower vehicle in short length spans. Inspect
at each interval for potential engine or transaxle contact
to vehicle components. Move the cradle/dolly fixture as
necessary to allow for installation clearance.
(2) Continue lowering vehicle until right side
engine mount and left side transaxle mount align to
their mounting locations. Install mounting bolts and
torque to 61 N·m (45 ft. lbs.).
(3) Remove safety straps from engine/transaxle
assembly. Slowly raise vehicle enough to remove the
engine dolly and cradle.
(4) Install A/C compressor.
(5) Connect A/C suction line to compressor.
(6) Install generator.
(7) Install intake manifold. Torque fasteners to 12
N·m (105 in. lbs.) (Refer to 9 - ENGINE/MANI-
FOLDS/INTAKE MANIFOLD - INSTALLATION).
(8) Connect generator connectors.
(9) Connect fuel line to fuel rail.
manifold
(Refer
to
MANIFOLD
(10) Connect brake booster and vapor purge hoses.
(11) Connect all ground straps to engine.
(12) Connect heater hose to thermostat housing.
(13) Connect coolant recovery container overflow
hose.
(14) Connect throttle and speed control cables.
9
-
(15) Connect ground cable to left side transaxle
-
mount bracket.
(16) Connect positive cable to battery and PDC.
(17) Raise vehicle on hoist.
(18) Install torque converter bolts.
(19) Install structural collar and torque reaction
bracket (Refer to 9 - ENGINE/ENGINE BLOCK/
STRUCTURAL COVER - INSTALLATION).
(20) Install rear mount bracket to transmission.
(21) Install front and rear engine mount through
bolts. Torque fasteners to 61 N·m (45 ft. lbs.).
(22) Connect exhaust pipe to exhaust manifold.
Torque fasteners to 28 N·m (250 in. lbs.).
(23) Connect A/C compressor electrical connectors.
(24) Connect heater return hose to pipe connection
at right front frame rail area.
(25) Install power steering pump to bracket.
(26) Install accessory drive belts (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(27) Install both axle shafts (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT - INSTALLATION).
(28) Install new oil filter.
(29) Install left and right splash shields.
(30) Install both front wheels.
(31) Lower vehicle.
(32) Connect engine electrical harness to PCM and
bulkhead connectors.
(33) Connect transmission shift cable.
(34) Connect transmission electrical connectors
(C104 & C105) (Refer to 8 - ELECTRICAL/CONNEC-
TOR/GROUND LOCATIONS - DESCRIPTION).
(35) Install cooling module assembly (radiator, fan
module, and condenser). Connect A/C lines to condenser.
(36) Connect transmission oil cooler lines using ser-
vice splice kit. Refer to instructions provided with kit.
(37) Connect upper and lower radiator hoses.
(38) Install upper radiator crossmember.
(39) Install throttle body air inlet hose and air
cleaner housing assembly.
(40) Fill engine crankcase with proper oil to cor-
rect level.
(41) Evacuate and recharge A/C system (Refer to
24 - HEATING & AIR CONDITIONING - STAN-
DARD PROCEDURE).
(42) Fill cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE).
(43) Connect negative battery cable.
(44) Start engine and run until normal operating
temperature is reached.
ENGINE 2.4L DOHC
9 - 83
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