GM Cavalier/Sunbird/Skyhawk/Firenza 1982-1994

Engine

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REMOVAL & INSTALLATION




CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

1982-83 1.8L and 2.0L Engines
  1. Disconnect the battery cables at the battery, negative cable first.
  2.  
  3. Remove the air cleaner. Drain the cooling system.
  4.  
  5. Remove the power steering pump (if so equipped) and position it out of the way. Leave the lines connected. Remove the windshield washer bottle and lay it aside.
  6.  
  7. If the car is equipped with A/C, remove the relay bracket at the bulkhead connector. Remove the bulkhead connector, then separate the wiring harness connections.
  8.  
  9. If equipped with cruise control, remove the servo bracket and position it out of the way.
  10.  
  11. Tag and disconnect all vacuum hoses and wires.
  12.  
  13. Unfasten the master cylinder attaching nuts at the vacuum booster, then lay it aside.
  14.  
  15. Detach the heater hose at the hot water pipe on the engine.
  16.  
  17. Remove the fan assembly. Remove the horn.
  18.  
  19. Disconnect the carburetor or TBI body linkage.
  20.  
  21. Raise the front of the car and support it with jackstands.
  22.  
  23. Properly relieve the fuel system pressure (see Routine Maintenance ), then disconnect the fuel line and the heater hose at the intake manifold.
  24.  
  25. If equipped with A/C, remove the air conditioning brace.
  26.  
  27. Remove the exhaust pipe shield.
  28.  
  29. As outlined in Engine Electrical of this repair guide, remove the starter.
  30.  
  31. Disconnect the exhaust pipe at the manifold.
  32.  
  33. Remove the front tire and wheel assemblies.
  34.  
  35. Disconnect the stabilizer bar from the lower control arms. Remove the ball joints from the steering knuckle.
  36.  
  37. Remove the drive axles at the transaxle, then remove the transaxle strut.
  38.  
  39. If equipped with A/C, remove the inner fender shield. Remove the drive belt, tag and disconnect the wires, then remove the compressor. Do NOT disconnect any of the refrigerant lines.
  40.  
  41. Remove the rear engine mount, nuts and plate.
  42.  
  43. If equipped with an automatic transaxle, remove the oil filter.
  44.  
  45. Disconnect the speedometer cable.
  46.  
  47. Carefully lower the vehicle.
  48.  
  49. If equipped with an automatic transaxle, disconnect the oil cooler lines at the transaxle.
  50.  
  51. Remove the front engine mount nuts.
  52.  
  53. For vehicles equipped with a manual transaxle, disconnect the clutch cable at the transaxle. For automatic transaxle equipped vehicles, disconnect the detent cable at the transaxle.
  54.  
  55. Remove the transaxle mount.
  56.  
  57. Install a suitable engine lifting device, Lift the engine and transaxle assembly out of the car.
  58.  

To install:
  1. Install the engine mount alignment bolt (M6 x 1 x 65) to ensure proper powertrain alignment.
  2.  
  3. Lower the engine into the car, leaving the lifting device attached.
  4.  
  5. Install the transaxle bracket. Install the mount to the side frame and secure with NEW mount bolts.
  6.  
  7. With the weight not yet on the mounts, tighten the transaxle bolts. Tighten the right front mount nuts.
  8.  
  9. Lower the engine fully onto the mounts, remove the lifting device and then raise the front of the car.
  10.  
  11. Installation of the remaining components is in the reverse order of removal. Check the powertrain alignment bolt; if excessive force is required to remove the bolt, loosen the transaxle adjusting bolts and realign the powertrain. Adjust the drive belts and the clutch cable (if equipped with manual transaxle).
  12.  
  13. Connect the negative battery cable, then start the engine and check for proper operation, fluid levels, and/or leaks.
  14.  

1984-86 1.8L (OHC) Engines
  1. Disconnect the negative, then positive battery cables. Detach the engine ground wire.
  2.  
  3. Properly drain the cooling system into a suitable container.
  4.  
  5. Remove the air cleaner.
  6.  
  7. Disconnect the radiator hoses.
  8.  
  9. Label and detach the following wires:

    Bulkhead (engine harness)
     
    Brake master cylinder
     
    A/C relay cluster switches (if equipped)
     
    Windshield wiper motor
     
    Cooling fan, relay and ground
     
    ECM (pull the harness through the bulkhead
     
    Temperature switch at the thermostat housing
     

  10.  
  11. Label and disconnect the fuel injection and MAP sensor and canister vacuum hoses.
  12.  
  13. Disconnect the throttle cable from the bracket and throttle body and the shift cable at the transaxle.
  14.  
  15. Detach the power steering hoses at the cut-off switch and the return hose at the pump.
  16.  
  17. Raise and safely support the vehicle.
  18.  
  19. Remove the speedometer cable and bracket.
  20.  
  21. Disconnect the exhaust pipe at the exhaust manifold and hangers, then position it aside.
  22.  
  23. Disconnect the hoses at the heater core, fuel lines and, if equipped with an automatic transaxle, the oil cooler lines.
  24.  
  25. Remove the front wheel and tire assemblies.
  26.  
  27. Remove the brake calipers. Be sure to support the calipers in the wheel opening with a piece of wire. Do NOT let the calipers hang by the brake line.
  28.  
  29. If equipped, disconnect the wires at the A/C compressor.
  30.  
  31. Using the proper equipment, evacuate the A/C system, then disconnect the lines from the compressor.
  32.  
  33. Remove the suspension supports. Remove the 2 center bolts on each side, then remove the bolt each end and loosen the remaining bolt.
  34.  


CAUTION
Be sure to properly support the vehicles, engine and transaxle weight during the following steps.

  1. For vehicles equipped with an automatic transaxle, remove the rear transaxle lateral strut.
  2.  
  3. Remove the transaxle strut (front).
  4.  
  5. Support the front of the car with jackstands under the radiator core support.
  6.  
  7. Reposition the jack to the rear of the cowl with a 4 in. x 4 in. x 6 ft. (102mm x 102mm x 1.8m) piece of wood spanning the vehicle's width.
  8.  
  9. Raise the car enough to remove the jackstands. Position a dolly under the engine and transaxle with three 4 in. x 4 in. x 12 in. (102mm x 102mm x 30cm) wood blocks as a support. Carefully, lower the weight of the car onto the dolly.
  10.  
  11. Remove the remaining bolt at each end of the right and left front suspension supports.
  12.  
  13. Unfasten the one long mount-to-bracket bolt, then remove the transaxle mount.
  14.  
  15. Remove the front engine mount. There should be 2 mount-to-bracket retaining bolts.
  16.  

The lower strut bolt opening is a slot, rather than a round hole. This is to allow for camber adjustment. Be sure to carefully scribe the position of the strut on the hub to preserve camber adjustments.

  1. Unfasten the knuckle-to-strut bolts. There are 2 per side.
  2.  
  3. Raise the car, leaving the engine, transaxle and suspension on the dolly. Separate the engine and transaxle.
  4.  

To install:
  1. With the aid of an assistant, assemble the engine and transaxle, then position in the chassis.
  2.  
  3. Install the transaxle mount, and secure by tightening the long mount-to-bracket bolt.
  4.  
  5. Install the rear engine mount, then secure using the 2 mount-to-bracket-bolts. Install the front engine mount the same way.
  6.  
  7. Loosely bolt each end of the right and left front suspension supports.
  8.  
  9. Making sure to align with the marks made during removal, install the knuckle-to-strut bolts. There are two on each side; tighten to 133 ft. lbs. (180 Nm).
  10.  
  11. Raise the car, then remove the dolly. Using jackstands, remove the 6 ft. (1.8m) piece of wood, then move the hoist to the front of the vehicle.
  12.  
  13. Install the remaining bolts in the right and left front suspension supports, then tighten to 65 ft. lbs. (88 Nm).
  14.  
  15. Install the front and rear transaxle struts.
  16.  
  17. If equipped, connect the wiring at the A/C compressor.
  18.  
  19. Remove the wire supporting the brake calipers, then install the calipers.
  20.  
  21. Install the front wheel and tire assemblies.
  22.  
  23. Connect the following hoses:

    Oil cooler lines (if equipped with an automatic transaxle)
     
    Fuel lines
     
    Heater core hoses.
     

  24.  
  25. Fasten the exhaust pipe to the manifold and hangers.
  26.  
  27. Connect the speedometer cable, then install the bracket.
  28.  
  29. Carefully lower the vehicle.
  30.  
  31. If equipped, connect the power steering return hose at the pump and the cut-off switch.
  32.  
  33. Connect the shift cable at the transaxle and the throttle cable to the bracket and throttle body assembly.
  34.  
  35. Attach the vacuum hoses to the MAP sensor and canister and the throttle body assembly.
  36.  
  37. Connect the following wires, as tagged during removal:

    Temperature switch at the thermostat housing
     
    ECM wiring (feed the harness through the bulkhead
     
    A/C relay cluster switches (if equipped)
     
    Windshield wiper motor
     
    Cooling fan, relay and ground
     
    Brake master cylinder
     
    Bulkhead (engine harness)
     

  38.  
  39. Connect the radiator hose(s).
  40.  
  41. Fill the cooling system with the proper type and quantity of suitable coolant.
  42.  
  43. If equipped, connect the A/C lines. Using the proper equipment, recharge the A/C system.
  44.  
  45. Connect the positive, then negative battery cables, then attach the engine ground wire.
  46.  

1984-89 2.0L (OHV) Engines
  1. Disconnect the negative, then the positive battery cables.
  2.  
  3. Properly drain the cooling system into a suitable container.
  4.  
  5. Remove the air cleaner assembly.
  6.  
  7. Disconnect the accelerator and T.V. cables at the throttle body.
  8.  
  9. Detach the ECM wiring harness at the throttle body.
  10.  
  11. Tag and disconnect all vacuum hoses, then remove the upper and lower radiator hoses and heater hoses at the engine.
  12.  
  13. Remove the exhaust heat shield.
  14.  
  15. For vehicles equipped with A/C, remove the adjustment bolt at the motor mount.
  16.  
  17. Disconnect the engine wiring harness at the bulkhead.
  18.  
  19. Remove the windshield washer bottle.
  20.  
  21. Remove the serpentine or alternator, power steering and A/C belts, as applicable.
  22.  
  23. If not done already, properly relieve the fuel system pressure. Disconnect the fuel lines.
  24.  
  25. Raise and safely support the vehicle.
  26.  
  27. If equipped with A/C, remove the A/C brace.
  28.  
  29. Remove the inner fender splash shield.
  30.  
  31. If equipped with A/C, remove the compressor, but do NOT disconnect the refrigerant lines.
  32.  
  33. Remove the flywheel splash shield.
  34.  
  35. Disconnect the starter wires.
  36.  
  37. Remove the front starter brace, then remove the starter as outlined in Engine Electrical of this repair guide.
  38.  
  39. Unfasten the torque converter bolts.
  40.  
  41. Remove the crankshaft pulley. Using tool J-24420 or equivalent, remove the crankshaft hub.
  42.  
  43. Remove the oil filter.
  44.  
  45. Unfasten and remove the engine-to-transaxle support bracket.
  46.  
  47. Remove the right rear motor mount.
  48.  
  49. Disconnect the exhaust pipe at the exhaust manifold, then disconnect the exhaust pipe at the center hanger and loosen the muffler hanger.
  50.  
  51. Remove the T.V. and shift cable bracket at the intake manifold.
  52.  
  53. Unfasten the 2 lower bellhousing bolts.
  54.  
  55. Carefully lower the vehicle.
  56.  
  57. Unfasten then remove the right front motor mount nuts.
  58.  
  59. Remove the alternator and adjusting brace.
  60.  
  61. Remove the brake master cylinder from the booster, then set aside, making sure it is suitably supported.
  62.  
  63. Install a suitable engine lifting device.
  64.  
  65. Remove the right front motor mount bracket.
  66.  
  67. Unfasten the remaining upper bellhousing bolts.
  68.  
  69. While lifting the engine, remove the power steering pump. Carefully lift the engine from the vehicle.
  70.  

To install:
  1. Position, then partially lower the engine assembly into the vehicle. Install the power steering pump, while lowering the engine.
  2.  
  3. Fasten the upper bellhousing bolts.
  4.  
  5. Install the right front motor mount bracket.
  6.  
  7. Remove the engine lifting device.
  8.  
  9. Fasten the master cylinder to the power brake booster.
  10.  
  11. Install the alternator and adjusting brace.
  12.  
  13. Install the right front motor mount nuts.
  14.  
  15. Raise and safely support the vehicle.
  16.  
  17. Install the remaining lower bellhousing bolts.
  18.  
  19. Install the T.V. and shift cable bracket.
  20.  
  21. Fasten the exhaust pipe at the center hanger, then tighten the muffler hanger. Connect the exhaust pipe at the exhaust manifold.
  22.  
  23. Install the right rear motor mount. If the rear engine mount bracket is removed, it will be necesary to perform the following steps to ensure proper engine mount bracket locations.
    1. Loosely install the engine mount bracket.
    2.  
    3. Raise the engine and transaxle.
    4.  
    5. Tighten the engine mount nuts and bolts.
    6.  

  24.  
  25. Install the engine-to-support bracket.
  26.  
  27. Install the oil filter.
  28.  
  29. Using the correct tool, install the crankshaft hub and pulley.
  30.  
  31. Install the torque converter retaining bolts.
  32.  
  33. Install the front starter brace, then the starter.
  34.  
  35. Connect the starter wires.
  36.  
  37. Install the flywheel splash shield.
  38.  
  39. If equipped with A/C, install the compressor.
  40.  
  41. Install the inner fender splash shield.
  42.  
  43. If equipped with A/C, install the A/C brace.
  44.  
  45. Carefully lower the vehicle.
  46.  
  47. Connect the fuel lines.
  48.  
  49. Install the serpentine, alternator, power steering and/or A/C belts, as applicable.
  50.  
  51. Install the windshield washer bottle.
  52.  
  53. Connect the engine wiring harness at the bulkhead.
  54.  
  55. For vehicles equipped with A/C, install the adjustment bolt at the motor mount.
  56.  
  57. Install the exhaust heat shield.
  58.  
  59. Connect the vacuum hoses and the upper and lower radiator hoses and heater hoses at the engine.
  60.  
  61. Attach the ECM harness at the engine.
  62.  
  63. Connect the accelerator and T.V. cables at the throttle body.
  64.  
  65. Install the air cleaner assembly.
  66.  
  67. Fill the engine cooling system with the correct amount and type of coolant.
  68.  
  69. Connect the postive, followed by the negative battery cables.
  70.  
  71. Start the engine, then inspect for proper brake system operation, proper fluid levels and/or leakage.
  72.  

2.0L (OHC) Engines

This procedure requires the use of a special tool.

  1. Remove battery cables.
  2.  
  3. Drain cooling system.
  4.  
  5. Remove air cleaner.
  6.  
  7. Disconnect engine electrical harness at bulkhead.
  8.  
  9. Disconnect electrical connector at brake cylinder.
  10.  
  11. Remove throttle cable from bracket and E.F.I. assembly.
  12.  
  13. Remove vacuum hoses from E.F.I. assembly.
  14.  
  15. Remove power steering high pressure hose at cut-off switch.
  16.  
  17. Remove vacuum hoses at the MAP sensor and canister.
  18.  
  19. Disconnect air conditioning relay cluster switches.
  20.  
  21. Remove power steering return hose at pump.
  22.  
  23. Disconnect ECM wire connections and feed harness through bulkhead and lay harness over engine.
  24.  
  25. Remove upper and lower radiator hoses from engine.
  26.  
  27. Remove electrical connections from temperature switch at thermostat housing.
  28.  
  29. Disconnect transmission shift cable at transmission.
  30.  
  31. Hoist car.
  32.  
  33. Remove speedometer cable at transmission and bracket.
  34.  
  35. Disconnect exhaust pipe at exhaust manifold.
  36.  
  37. Remove exhaust pipe from converter.
  38.  
  39. Remove heater hoses from heater core.
  40.  
  41. Remove fuel lines at flex hoses.
  42.  
  43. Remove transmission cooler lines at flex hoses.
  44.  
  45. Remove left and right front wheels.
  46.  
  47. Remove right hand spoiler section and splash shield.
  48.  
  49. Remove right and left brake calipers and support with wire.
  50.  
  51. Remove right and left tie rod ends.
  52.  
  53. Disconnect electrical connections at air conditioning compressor.
  54.  
  55. Remove air conditioning compressor and mounting brackets, support air conditioning compressor with wire in wheel opening.
  56.  
  57. Remove front suspension support attachment bolts (6 bolts each side).
  58.  
  59. Lower car.
  60.  
  61. Support front of vehicle by placing two short jackstands under core support.
  62.  
  63. Position front post hoist to the rear of cowl.
  64.  
  65. Position a 4 in. (102mm) x 4 in. (102mm) x 6 ft. (2m) timber on front post hoist.
  66.  
  67. Raise vehicle enough to remove jackstands.
  68.  
  69. Position a 4-wheel dolly under engine and transaxle assembly.
  70.  
  71. Position three (3) 4 in. (102mm) x 4 in. (102mm) x 12 in. (305mm) blocks under engine and transaxle assembly only, letting support rails hang free.
  72.  
  73. Lower vehicle onto 4-wheel dolly slightly.
  74.  
  75. Remove rear transaxle mount attachment bolts (2).
  76.  
  77. Remove left front engine mount attachment bolts (3).
  78.  
  79. Remove two (2) engine support to body attachment bolts behind right-hand inner axle U-joint.
  80.  
  81. Remove one (1) attaching bolt and nut from right-hand chassis side rail to engine mount bracket.
  82.  
  83. Remove six (6) strut attachment nuts.
  84.  
  85. Raise vehicle letting engine, transaxle and suspension resting on 4-wheel dolly.
  86.  

Reverse the removal procedure for engine installation with the following exceptions:

  1. With one man's assistance, position engine and transaxle assembly in chassis.
  2.  
  3. Install transaxle and left front mounts to side rail bolts loosely.
  4.  
  5. Install a M6 x 1 x 65 alignment bolt in left front mount to prevent powertrain misalignment.
  6.  
  7. Tighten the transaxle mount bolts to 42 ft. lbs. and left front mount bolts to 18 ft. lbs.
  8.  
  9. Install right rear mount to body bolts and tighten to 38 ft. lbs. (52 Nm).
  10.  
  11. Install right rear mount to chassis side rail bolt and nut, then tighten to 38 ft. lbs. (52 Nm).
  12.  
  13. Place a floor jack under control arms, jack struts into position and install retaining nuts.
  14.  
  15. Raise vehicle.
  16.  
  17. Using a transmission jack or suitable lifting equipment, raise control arms and attach tie rod ends.
  18.  

2.2L Engines
1990-93 VEHICLES

The following procedure is for the engine and transaxle assembly.

  1. Disconnect the battery.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Disconnect the hood lamp wiring, if so equipped and remove the hood.
  8.  
  9. Disconnect the throttle body intake duct.
  10.  
  11. Remove the rear sight shields.
  12.  
  13. Disconnect the upper radiator hose.
  14.  
  15. Disconnect the brake booster vacuum hose.
  16.  
  17. Disconnect the alternator top brace and wiring.
  18.  
  19. Disconnect and tag the upper engine harness from the engine.
  20.  
  21. Discharge the A/C system as outlined in Routine Maintenance .
  22.  
  23. Disconnect the A/C compressor to condenser and accumulator lines.
  24.  
  25. Raise and support the vehicle safely.
  26.  
  27. Remove the left splash shield.
  28.  
  29. Disconnect the exhaust system.
  30.  
  31. Disconnect and tag the lower engine wiring.
  32.  
  33. Remove the flywheel inspection cover.
  34.  
  35. Remove the front wheels.
  36.  
  37. Disconnect the lower radiator hose.
  38.  
  39. Disconnect the heater hoses from the heater core.
  40.  
  41. Remove the brake calipers from the steering knuckle and wire up out of the way as outlined in Brakes .
  42.  
  43. Disconnect the tie rods from the struts.
  44.  
  45. Lower the vehicle.
  46.  
  47. Remove the clutch slave cylinder.
  48.  
  49. With the fuel system pressure released, place an absorbent shop towel around the connections and disconnect the fuel lines.
  50.  
  51. Disconnect the transaxle linkage at the transaxle.
  52.  
  53. Disconnect the accelerator cables from the TBI unit.
  54.  
  55. Disconnect the cruise control cables from the TBI unit.
  56.  
  57. Disconnect the throttle valve cables from the TBI, on vehicles equipped with an automatic transaxle.
  58.  
  59. Disconnect the automatic transaxle cooling lines.
  60.  
  61. Disconnect the power steering hoses from the power steering pump.
  62.  
  63. Remove the center suspension support bolts.
  64.  
  65. Align Engine/Transaxle Frame Handler tool No. J 36295 or equivalent under the suspension supports, engine and transaxle; lower vehicle to dolly and add support under the engine.
  66.  
  67. Safely support the rear of the vehicle.
  68.  
  69. Disconnect the upper transaxle mount.
  70.  
  71. Remove the upper strut bolts and nuts.
  72.  
  73. Disconnect the front engine mount.
  74.  
  75. Disconnect the rear engine mount.
  76.  
  77. Remove the 4 rear suspension support bolts.
  78.  
  79. Remove the 4 front suspension support bolts and wire the bolt holes together to prevent axle separation.
  80.  
  81. Raise the vehicle and remove the engine and transaxle assembly on tool No. J 36295 or equivalent.
  82.  

To install:
  1. Lower the vehicle and install the engine and transaxle assembly using tool No. J 36295 or equivalent.
  2.  
  3. Install the suspension supports bolts and tighten to 65 ft. lbs. for the front and rear suspension supports and 66 ft. lbs. for the center suspension support.
  4.  
  5. Install the transaxle mount but do not tighten.
  6.  
  7. Install the rear engine mount but do not tighten.
  8.  
  9. Install the front engine mount but do not tighten.
  10.  
  11. Tighten the manual transaxle mounting bolts as follows:

    Front transaxle strut to body bolts to 40 ft. lbs.
     
    Rear transaxle mount to body bolts to 23 ft. lbs.
     

  12.  
  13. Tighten the automatic transaxle mount bolts to 22 ft. lbs.
  14.  
  15. Tighten the front and rear engine mount bolts, please refer to the engine mount illustration.
  16.  

All engine mount bolts that have been removed must be cleaned and a new thread locking compound applied to the threads before reinstallation.

  1. Install the power steering hoses.
  2.  
  3. Connect the accelerator, cruise control and T.V. cables to the TBI.
  4.  
  5. Connect the transaxle cooling lines to the automatic transaxle.
  6.  
  7. Connect the transaxle linkage.
  8.  
  9. Reconnect the fuel lines.
  10.  
  11. Reconnect the clutch slave cylinder.
  12.  
  13. Raise and support the vehicle safely.
  14.  
  15. Install the tie rods.
  16.  
  17. Install the calipers to the steering knuckle.
  18.  
  19. Install the heater hoses to the heater core.
  20.  
  21. Install the lower radiator hose.
  22.  
  23. Install the A/C compressor.
  24.  
  25. Install the flywheel inspection cover.
  26.  
  27. Install the engine splash shield.
  28.  
  29. Install the front wheel and tighten the wheel stud nuts to 100 ft. lbs. (136 Nm).
  30.  
  31. Lower the vehicle.
  32.  
  33. Install the upper engine wiring.
  34.  
  35. Install the compressor to condenser and accumulator lines.
  36.  
  37. Install the brake booster vacuum hose.
  38.  
  39. Install the upper radiator hose.
  40.  
  41. Raise and support the vehicle safely.
  42.  
  43. Install the lower engine wiring.
  44.  
  45. Reconnect the exhaust system.
  46.  
  47. Lower the vehicle.
  48.  
  49. Connect the TBI wiring.
  50.  
  51. Install the air cleaner assembly.
  52.  
  53. Recharge the A/C system.
  54.  
  55. Check and adjust the wheel alignment.
  56.  
  57. Install the hood and connect the battery.
  58.  

1994 VEHICLES
  1. Properly relieve the fuel system pressure, then disconnect the negative battery cable.
  2.  
  3. Drain the cooling system into a suitable container.
  4.  
  5. Remove the air cleaner outlet duct.
  6.  
  7. Detach the upper radiator hose at the coolant outlet.
  8.  
  9. Disconnect the brake booster vacuum hose.
  10.  
  11. Tag and detach the following electrical connections:

    Idle Air Control (IAC)
     
    Alternator
     
    Throttle Position (TP) sensor
     
    Manifold Absolute Pressure (MAP) sensor
     
    EVAP emission solenoid
     
    Fuel injector harness
     
    Exhaust Gas Recirculation (EGR) valve
     
    Engine Coolant Temperature (ECT) sensor
     
    Transaxle Converter Clutch (TCC)
     
    Oxygen (O 2 ) sensor
     
    Park/Neutral position switch
     
    Engine grounds
     

  12.  
  13. Remove the serpentine drive belt.
  14.  
  15. Disconnect the transaxle shift control cable from the range select lever and bracket.
  16.  
  17. Detach the coolant surge tank hose, then remove the tank.
  18.  
  19. Disconnect the vacuum line near the master cylinder.
  20.  
  21. Install J 28467-A or equivalent engine support fixture.
  22.  
  23. Disconnect the lower radiator hose from the water pump.
  24.  
  25. Raise and safely support the vehicle.
  26.  
  27. Remove both front wheel and tire assemblies, then remove both splash shields.
  28.  
  29. Disconnect the exhaust pipe at the manifold and catalytic converter.
  30.  
  31. Remove the engine mount strut.
  32.  
  33. Disconnect the wheel speed sensor wire harness from the control arms.
  34.  
  35. Separate the ball joints from the steering knuckles. Using tool J 24319-01 or equivalent, separate the tie rod ends from the struts.
  36.  
  37. Detach the brake lines from the suspension supports.
  38.  
  39. If equipped, remove the A/C compressor and support with the lines attached.
  40.  
  41. Tag and detach the following electrical connectors:

    Electronic Ignition Module
     
    Vehicle Speed Sensors (VSS)
     
    Cooling Fan
     
    Starter
     
    A/C compressor
     
    Oil pressure and level sensors
     
    Engine grounds
     

  42.  
  43. Disconnect the power steering lines from the rack and pinion assembly. Detach the flexible coupling joint at the rack and pinion assembly.
  44.  
  45. Disconnect the accelerator control, cruise control (if equipped) and the T.V. cables from the accelerator control bracket.
  46.  
  47. Remove the suspension support assembly.
  48.  
  49. Disconnect the heater hoses at the front of the dash.
  50.  
  51. Remove both drive axles from the transaxle, then position them aside.
  52.  
  53. Disconnect the fuel lines.
  54.  
  55. Detach the cooler lines from the transaxle, then remove the transaxle mount.
  56.  
  57. Remove the engine mount assembly.
  58.  
  59. Place a suitable support under the vehicle. Carefully lower the vehicle so that it rests lightly on the support.
  60.  
  61. Remove the support fixture from the engine, then raise the vehicle, leaving the engine and transaxle assembly on the table.
  62.  
  63. Unfasten the retaining bolts, then separate the engine from the transaxle.
  64.  

To install:
  1. Position the engine to the transaxle, then install the retaining bolts. Tighten the bolts to 55 ft. lbs. (75 Nm).
  2.  
  3. Lower the vehicle onto the engine and transaxle assembly.
  4.  
  5. Install J 28467-A or equivalent engine support fixture onto the engine.
  6.  
  7. Install the engine mount assembly, then install the transaxle mount.
  8.  
  9. Attach the cooler lines to the transaxle.
  10.  
  11. Connect the fuel lines.
  12.  
  13. Install both drive axles into the transaxle.
  14.  
  15. Connect the heater hoses to the front of the cowl.
  16.  
  17. Install the suspension support assembly.
  18.  
  19. Connect the accelerator, cruise control, and T.V. cables to the accelerator control bracket.
  20.  
  21. Attach the flexible coupling joint to the rack and pinion assembly.
  22.  
  23. Connect the power steering lines to the rack and pinion assembly.
  24.  
  25. Attach the following electrical connectors as tagged during removal:

    Electronic Ignition Module
     
    Vehicle Speed Sensors (VSS)
     
    Cooling Fan
     
    Starter
     
    A/C compressor
     
    Oil pressure and level sensors
     
    Engine grounds
     

  26.  
  27. Install the A/C compressor, if equipped.
  28.  
  29. Connect the brake lines to the suspension support.
  30.  
  31. Fasten the tie rod ends to the struts, then connect the ball joints to the steering knuckles.
  32.  
  33. Connect the wheel speed sensor wire harness to the control arms.
  34.  
  35. Install the engine mount strut.
  36.  
  37. Fasten the exhaust pipe to the exhaust manifold and catalytic converter.
  38.  
  39. Install the splash shields and the wheel and tire assemblies.
  40.  
  41. Carefully lower the vehicle.
  42.  
  43. Connect the lower radiator hose to the water pump.
  44.  
  45. Remove the engine support fixture.
  46.  
  47. Attach the vacuum line, located near the master cylinder.
  48.  
  49. Install the coolant surge tank, then connect the tank's hose.
  50.  
  51. Connect the transaxle shift control cable.
  52.  
  53. Install the serpentine drive belt.
  54.  
  55. Attach the following electrical connectors, as tagged during removal:

    Idle Air Control (IAC)
     
    Alternator
     
    Throttle Position (TP) sensor
     
    Manifold Absolute Pressure (MAP) sensor
     
    EVAP emission solenoid
     
    Fuel injector harness
     
    Exhaust Gas Recirculation (EGR) valve
     
    Engine Coolant Temperature (ECT) sensor
     
    Transaxle Converter Clutch (TCC)
     
    Oxygen (O 2 ) sensor
     
    Park/Neutral position switch
     
    Engine grounds
     

  56.  
  57. Connect the brake booster vacuum hose.
  58.  
  59. Attach the upper radiator hose and the air cleaner outlet duct.
  60.  
  61. Fill the cooling system and crankcase with the correct type and amount of fluids.
  62.  
  63. Connect the negative battery cable, then start the engine. Check for proper operation, fluid levels and/or leaks.
  64.  

2.8L and 3.1L Engines
1985-88 VEHICLES
  1. Disconnect the negative battery cable. Drain the cooling system and remove the air cleaner assembly.
  2.  
  3. Remove the air flow sensor. Remove the exhaust crossover heat shield and remove the crossover pipe.
  4.  
  5. Remove the serpentine belt tensioner and belt.
  6.  
  7. Remove the power steering pump mounting bracket. Disconnect the heater pipe at the power steering pump mounting bracket.
  8.  
  9. Disconnect the radiator hoses from the engine.
  10.  
  11. Disconnect the accelerator and throttle valve cable at the throttle valve.
  12.  
  13. Remove the alternator. Tag and disconnect the wiring harness at the engine.
  14.  
  15. Relieve the fuel pressure (see Routine Maintenance ) and disconnect the fuel hose. Disconnect the coolant bypass and the overflow hoses at the engine.
  16.  
  17. Tag and remove the vacuum hoses to the engine.
  18.  
  19. Raise the vehicle and support it safely.
  20.  
  21. Remove the inner fender splash shield. Remove the harmonic balancer.
  22.  
  23. Remove the flywheel cover. Remove the starter bolts. Tag and disconnect the electrical connections to the starter. Remove the starter.
  24.  
  25. Disconnect the wires at the oil sending unit.
  26.  
  27. Remove the air conditioning compressor and related brackets.
  28.  
  29. Disconnect the exhaust pipe at the rear of the exhaust manifold.
  30.  
  31. Remove the flex plate-to-torque converter bolts.
  32.  
  33. Remove the transaxle-to-engine bolts. Remove the engine-to-rear mount frame nuts.
  34.  
  35. Disconnect the shift cable bracket at the transaxle. Remove the lower bell housing bolts.
  36.  
  37. Lower the vehicle and disconnect the heater hoses at the engine.
  38.  
  39. Install a suitable engine lifting device. While supporting the engine and transaxle, remove the upper bell housing bolts.
  40.  
  41. Remove the front mounting bolts.
  42.  
  43. Remove the master cylinder from the booster.
  44.  
  45. Remove the engine assembly from the vehicle.
  46.  

To install:
  1. Install the engine and remove the engine lifting device.
  2.  
  3. Install the master cylinder to the booster.
  4.  
  5. Install the front mounting bolts.
  6.  
  7. Install the upper bell housing bolts.
  8.  
  9. Connect the heater hoses at the engine.
  10.  
  11. Connect the shift cable bracket at the transaxle. Install the lower bell housing bolts.
  12.  
  13. Install the transaxle-to-engine bolts. Install the engine-to-rear mount frame nuts.
  14.  
  15. Install the flex plate-to-torque converter bolts.
  16.  
  17. Connect the exhaust pipe at the rear of the exhaust manifold.
  18.  
  19. Install the air conditioning compressor and related brackets.
  20.  
  21. Connect the wires at the oil sending unit.
  22.  
  23. Install the flywheel cover. Install the starter bolts. Connect the electrical connections to the starter. Install the starter.
  24.  
  25. Install the inner fender splash shield. Install the harmonic balancer.
  26.  
  27. Lower the vehicle.
  28.  
  29. Install the vacuum hoses to the engine.
  30.  
  31. Connect the fuel hose. Connect the coolant bypass and the overflow hoses at the engine.
  32.  
  33. Install the alternator. Connect the wiring harness at the engine.
  34.  
  35. Connect the accelerator and throttle valve cable at the throttle valve.
  36.  
  37. Connect the radiator hoses to the engine.
  38.  
  39. Install the power steering pump mounting bracket. Connect the heater pipe at the power steering pump mounting bracket.
  40.  
  41. Install the serpentine belt tensioner and belt.
  42.  
  43. Install the air flow sensor. Install the exhaust crossover heat shield and crossover pipe.
  44.  
  45. Connect the negative battery cable. Fill the cooling system and install the air cleaner assembly.
  46.  

1989-93 VEHICLES
  1. Disconnect the negative battery cable. Properly drain the cooling system into a suitable container.
  2.  
  3. Remove the air cleaner and duct assembly.
  4.  
  5. Disconnect the exhaust manifold/crossover assembly.
  6.  
  7. Remove the serpentine belt tensioner and idler, if equipped.
  8.  
  9. Detach the radiator hoses from the engine.
  10.  
  11. Disconnect the cables from the bracket at the plenum.
  12.  
  13. Remove the alternator. Tag and disconnect the wiring harness at the engine.
  14.  
  15. Relieve the fuel pressure (see Routine Maintenance ) and disconnect the fuel hose.
  16.  
  17. Disconnect the coolant bypass and the overflow hoses at the engine.
  18.  
  19. Support the engine using J 28467-A or equivalent engine support fixture.
  20.  
  21. Raise and safely support the vehicle.
  22.  
  23. Remove the inner fender splash shield.
  24.  
  25. Remove the flywheel cover.
  26.  
  27. Unfasten the starter bolts. Tag and detach the electrical connections to the starter, then remove the starter.
  28.  
  29. Remove the air conditioning compressor and related brackets.
  30.  
  31. Disconnect the exhaust pipe at the rear of the exhaust manifold.
  32.  
  33. Remove the flywheel-to-torque converter bolts.
  34.  
  35. Disconnect the engine mounts.
  36.  
  37. If equipped with a manual transaxle, disconnect the intermediate shaft bracket to the engine.
  38.  
  39. Disconnect the shift cable bracket at the transaxle. Remove the lower bell housing bolts.
  40.  
  41. Carefully lower the vehicle, then disconnect the heater hoses at the engine.
  42.  
  43. Install a suitable engine lifting device. While supporting the engine and transaxle, remove the J 28467-A engine support fixture.
  44.  
  45. Support the transaxle, then remove the transaxle bolts.
  46.  
  47. Remove the engine assembly from the vehicle.
  48.  

To install:
  1. Install J 28467-A engine support fixture, or equivalent.
  2.  
  3. Remove the engine lifting device.
  4.  
  5. Support the transaxle, then install the transaxle bolts.
  6.  
  7. Connect the heater hoses at the engine.
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Fasten the lower bell housing bolts.
  12.  
  13. Install the shift cable bracket at the transaxle.
  14.  
  15. If equipped with a manual transaxle, connect the intermediate shaft bracket to the engine.
  16.  
  17. Reconnect the engine mounts, then tighten as follows:

    Front engine mount-to-bracket bolt to 50 ft. lbs. (68 Nm).
     
    Front engine mount-to-frame bolt (top) to 54 ft. lbs. (73 Nm).
     
    Front engine mount-to-frame bolt (bottom) to 61 ft. lbs. (83 Nm).
     
    Engine mount bracket-to-body lower bolt to 47 ft. lbs. (64 Nm).
     
    Engine mount bracket-to-body upper bolt to 74 ft. lbs. (100 Nm).
     
    Rear engine mount-to-engine bolt to 40 ft. lbs. (54 Nm).
     
    Rear engine bracket-to-body bolt to 45 ft. lbs. (61 Nm).
     

  18.  

All engine mount bolts that have been removed must be cleaned and a new thread locking compound applied to the threads before reinstallation.

  1. Install the flywheel-to-torque converter bolts.
  2.  
  3. Connect the exhaust pipe at the rear of the exhaust manifold.
  4.  
  5. Install the air conditioning compressor.
  6.  
  7. Install the starter.
  8.  
  9. Fasten the flywheel cover.
  10.  
  11. Install the inner fender splash shield.
  12.  
  13. Carefully lower the vehicle, then remove J 28467-A engine support fixture, or equivalent.
  14.  
  15. Connect the coolant bypass and the overflow hoses at the engine.
  16.  
  17. Reconnect the fuel lines.
  18.  
  19. Attach the wiring harness at the engine.
  20.  
  21. Install the alternator.
  22.  
  23. Connect the cables from the bracket at the plenum.
  24.  
  25. Fasten the radiator hoses.
  26.  
  27. Install the serpentine belt tensioner and idler, if equipped.
  28.  
  29. Refill the cooling system to the correct level with the proper type of coolant.
  30.  
  31. Install the air cleaner and duct assembly.
  32.  
  33. Connect the battery cable(s), then start the engine and check for proper operation and/or leaks.
  34.  

1994 VEHICLES

On these 3.1L engines, an "Idle Learn" procedure must be performed which requires the use of a scan tool.

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative, then positive battery cables, then remove the battery from the vehicle.
  4.  
  5. Remove the air cleaner assembly.
  6.  
  7. Properly drain the cooling system into an approved container.
  8.  
  9. For vehicles equipped with a manual transaxle, remove the left side sound insulator, then disconnect the push rod from the clutch pedal.
  10.  
  11. Disconnect the exhaust crossover pipe from the exhaust manifolds.
  12.  
  13. Remove the serpentine drive belt.
  14.  
  15. Disconnect the coolant bleed hose from the pipe. Disconnect the radiator hoses from the themostat housing and water pump. Remove the cooling fan assembly.
  16.  
  17. Disconnect the throttle, cruise control and T.V. cables from the throttle body.
  18.  
  19. Detach the power steering line from the bracket behind the alternator.
  20.  
  21. Remove the rear alternator brace, then the alternator.
  22.  
  23. Tag and detach the following electrical connections at the engine:

    Oxygen (O 2 ) sensor
     
    Engine Coolant Temperature (ECT) sensor
     
    EGR valve
     
    Manifold Absolute Pressure (MAP) sensor
     
    Idle Air Control (IAC) valve
     
    Throttle Position (TP) sensor
     
    Transaxle Converter Clutch (TCC)
     
    Park/Neutral Position switch (vehicles with an automatic transaxle only)
     
    Back-up Light switch (vehicles with a manual transaxle only)
     
    Ground connections
     

  24.  
  25. Disconnect the fuel lines.
  26.  
  27. Detach the coolant bypass hose at the engine.
  28.  
  29. Tag and disconnect all vacuum hoses from the engine.
  30.  
  31. Detach the power steering pressure and return lines.
  32.  
  33. Unfasten the clutch actuator cylinder quick disconnect fitting.
  34.  
  35. Disconnect the shift cables from the transaxle.
  36.  
  37. Unfasten the nuts from the top of the strut towers to allow tool J 28467-A, or equivalent, to be installed. Support the vehicles using tool J 28467-A or equivalent.
  38.  
  39. Remove the transaxle mount and bracket as an assembly.
  40.  
  41. Loosen the A/C accumulator bracket, then raise the accumulator a few inches to gain access to the upper front engine mount bolts. Remove the upper fasteners from the front engine mount.
  42.  
  43. Raise and safely support the vehicle.
  44.  
  45. Remove the front tire and wheel assemblies.
  46.  
  47. Remove the front air deflector and the right front splash shield.
  48.  
  49. If equipped, detach the front ABS wheel speed sensor connectors and harnesses from the suspension support.
  50.  
  51. Remove both front ball joints. For details, please refer to the procedure located in Suspension & Steering of this repair guide.
  52.  
  53. Detach the engine mount strut from the transaxle bracket. Remove the front suspension support.
  54.  
  55. Remove the oil pressure switch from the engine.
  56.  

Make sure to use rags or shop towels between the A/C compressor and the radiator to prevent damage to the radiator cooling fins.

  1. If equipped, remove the A/C compressor, leaving the lines attached, Support the compressor on the lower radiator tie-bar.
  2.  
  3. Disconnect the exhaust pipe at the rear of the manifold..
  4.  
  5. Detach the drive axles from the transaxles. Remove the strut mount bracket.
  6.  
  7. Tag and detach the following lower electrical connectors:

    Electronic Ignition system module
     
    Knock sensor
     
    Vehicle Speed Sensor (VSS)
     
    Connections at the starter
     
    Secondary ignition wires from the coils
     

  8.  
  9. As outlined in Engine Electrical of this repair guide, remove the starter.
  10.  
  11. Remove the flywheel housing or transaxle converter cover.
  12.  
  13. For vehicles equipped with a manual transaxle, remove the intermediate shaft bracket from the engine.
  14.  
  15. For vehicles equipped with an automatic transaxle, remove the shift cable bracket at the transaxle (press fit).
  16.  
  17. Disconnect the automatic transaxle cooler lines from the transaxle, if applicable.
  18.  
  19. Unfasten the lower engine mount bolts, then remove the rear engine mount.
  20.  
  21. Disconnect the heater hoses from the front of the dash.
  22.  
  23. Carefully lower the vehicle enough to place an engine/transaxle table under the vehicle.
  24.  
  25. Remove the engine and transaxle assembly from the vehicle.
  26.  
  27. Detach the transaxle selector cable bracket.
  28.  
  29. Unfasten the bolt, the remove the automatic transaxle fluid level indicator and fill tube assembly.
  30.  
  31. Remove the rear engine mount assembly from the engine, then remove the transaxle-to-engine bracket.
  32.  
  33. Unfasten the flywheel-to-torque converter bolts, then separate the engine from the transaxle.
  34.  

To install:
  1. Fasten the engine to the transaxle.
  2.  
  3. Install the flywheel-to-torque converter bolts.
  4.  
  5. Install the transaxle-to-engine bracket, then attach the rear engine mount assembly to the engine.
  6.  
  7. Position the automatic transaxle fluid level indicator and fill tube assembly and secure with the retaining bolt.
  8.  
  9. Install the transaxle selector cable bracket.
  10.  
  11. Carefully lower the vehicle enough to place an engine/transaxle table under the vehicle.
  12.  
  13. Position the engine and transaxle assembly into the vehicle.
  14.  
  15. Install the rear engine mount, then install the lower engine mount bolts.
  16.  
  17. Connect the heater hoses to the front of the dash.
  18.  
  19. Attach the automatic transaxle cooler lines to the transaxle, if applicable.
  20.  
  21. Install the shift cable bracket (press fit) to the automatic transaxle.
  22.  
  23. If equipped with a manual transaxle, fasten the intermediate shaft bracket to the engine.
  24.  
  25. Install the electronic ignition system coil and module assembly.
  26.  
  27. Fasten the flywheel housing or transaxle converter cover.
  28.  
  29. Install the starter, as outlined in Engine Electrical of this repair guide.
  30.  
  31. Attach the following electrical connectors, as tagged during removal:

    Electronic Ignition system module
     
    Knock sensor
     
    Vehicle Speed Sensor (VSS)
     
    Electrical connections at the starter
     
    Secondary ignition (spark plug) wires to the coils
     

  32.  
  33. Install the strut mount bracket.
  34.  
  35. Fasten the drive axles to the transaxle.
  36.  
  37. Attach the exhaust pipe to the rear of the manifold.
  38.  
  39. Remove the shop towels or rag from the lower radiator tie-bar, then install the A/C compressor.
  40.  
  41. Install the oil pressure switch.
  42.  
  43. Install the front suspension support, then install the engine mount strut-to-transaxle bracket.
  44.  
  45. As outlined in Suspension & Steering of this repair guide, install both front ball joints.
  46.  
  47. If equipped, attach the front ABS wheel speed sensor connectors and harnesses to the suspension support.
  48.  
  49. Install the right front splash shield and the front air deflector.
  50.  
  51. Install both front tire and wheel assemblies, then carefully lower the vehicle.
  52.  
  53. Attach the upper fasteners to the front engine mount.
  54.  
  55. After carefully pushing the A/C accumulator back into place, tighten the accumulator bracket.
  56.  
  57. Install the transaxle mount and bracket as an assembly.
  58.  
  59. Remove tool J 28467-A or equivalent engine support fixture, then install the retaining nuts to the top of the strut towers.
  60.  
  61. Connect the transaxle shift cables.
  62.  
  63. For vehicles equipped with a manual transaxle, install the clutch actuator cylinder.
  64.  
  65. Connect the power steering pressure and return lines.
  66.  
  67. Attach all vacuum hoses, as tagged during removal.
  68.  
  69. Fasten the coolant bypass hose.
  70.  
  71. Connect the fuel lines.
  72.  
  73. Attach the following electrical connections, as tagged during removal:

    Ground connections
     
    Back-up Light switch (vehicles with a manual transaxle only)
     
    Park/Neutral Position switch (vehicles with an automatic transaxle only)
     
    Transaxle Converter Clutch (TCC)
     
    Throttle Position (TP) sensor
     
    Idle Air Control (IAC) valve
     
    Manifold Absolute Pressure (MAP) sensor
     
    EGR valve
     
    Engine Coolant Temperature (ECT) sensor
     
    Oxygen (O 2 ) sensor
     

  74.  
  75. Install the alternator, as outlined in Engine Electrical of this repair guide. Install the rear alternator brace.
  76.  
  77. Attach the power steering line.
  78.  
  79. Connect the throttle, cruise control (if equipped) and the T.V. cables to the throttle body.
  80.  
  81. Install the coolant fan assembly.
  82.  
  83. Attach the radiator hoses and the coolant bleed hose.
  84.  
  85. Install the serpentine belt.
  86.  
  87. Fasten the exhaust crossover pipe to the exhaust manifolds.
  88.  
  89. If equipped with a manual transaxle, fasten the push rod and left side sound insulator to the clutch pedal.
  90.  
  91. Install the air cleaner assembly, then install the battery. Connect the positive, then negative battery cables.
  92.  
  93. Fill the coolant, oil, transaxle and power steering fluids to the proper levels.
  94.  

On the 3.1L engine, a Tech 1® scan tool is needed to perform the "Idle Learn" procedure.

  1. For the 3.1L engine perform the following "Idle Learn" procedure;
    1. Install a Tech 1® scan tool.
    2.  
    3. Turn the ignition to the ON position, engine not running.
    4.  
    5. Select IAC SYSTEM , then IDLE LEARN in the MISC TEST mode.
    6.  
    7. Place the transaxle in park or neutral, as applicable.
    8.  
    9. Proceed with idle learn as directed by the scan tool.
    10.  

  2.  
  3. Bleed the power steering system.
  4.  
  5. Start the engine, then check for proper fluid levels and/or leaks.
  6.  

 
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