GM Celebrity/Century/Ciera/6000 1982-1996 Repair Guide

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.

2.2L Engine

CAUTION
The fuel system is under pressure and must have the pressure relieved prior to disconnecting the fuel lines. Failure to properly bleed the system can lead to personal injury.

  1. Relieve the fuel pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system into a suitable container.
  6.  
  7. While supporting the hood, disconnect the hydraulic shock from the cowl pan and secure the hood in a fully open position.
  8.  
  9. Remove the air cleaner and air duct assembly.
  10.  
  11. Disconnect the control cables from the throttle body and remove the control cable bracket from the intake manifold and rocker arm cover. Set the assembly out of the way.
  12.  
  13. Disconnect and cap the fuel lines from the throttle body and manifold mounting bracket.
  14.  
  15. Tag and disconnect any vacuum hoses that will interfere with the engine removal.
  16.  
  17. Remove the upper and lower radiator hoses.
  18.  
  19. Disconnect the heater hoses from the intake manifold and the water pump, then secure them out of the way.
  20.  
  21. Remove the torque strut.
  22.  
  23. Disconnect the engine harness wiring, then rotate the engine forwards.
  24.  
  25. Remove the power steering pump from the engine an support it out of the way with the power steering lines attached.
  26.  
  27. Disconnect the electrical wiring from the rear of the engine.
  28.  
  29. Remove the transaxle oil fill tube.
  30.  
  31. Remove the transaxle-to-engine bolts leaving in only the two upper bolts.
  32.  
  33. Rotate the engine to it's normal position.
  34.  
  35. Loosen the right front wheel lug nuts, then raise and support the vehicle.
  36.  
  37. Remove the right front tire and wheel assembly.
  38.  
  39. Remove the right inner fender well splash shield.
  40.  
  41. Disconnect the exhaust pipe from the exhaust manifold.
  42.  
  43. Remove the flywheel cover.
  44.  
  45. Disconnect and remove the starter.
  46.  
  47. Remove the engine mount-to-frame nuts.
  48.  
  49. Remove the torque converter-to-flywheel bolts.
  50.  
  51. Remove the A/C compressor from the mounting bracket and secure out of the way to the side without disconnecting the refrigerant lines.
  52.  
  53. Remove the front pipe support bracket from the transaxle.
  54.  
  55. Remove the transaxle support bracket from the transaxle and frame.
  56.  
  57. Lower the vehicle.
  58.  
  59. Remove the two remaining engine-to-transaxle mounting bolts.
  60.  
  61. Attach a suitable lifting device and slowly remove the engine. While lifting out the engine, make sure that no hoses or electrical connectors are still attached.
  62.  

To install:
  1. Lower the engine into the vehicle and connect the engine to the transaxle.
  2.  
  3. Install the two upper engine-to-transaxle bolts. Tighten the bolts only until snug.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Install the transaxle support bracket and tighten the mounting bolts to 38 ft. lbs. (52 Nm).
  8.  
  9. Install the front exhaust pipe-to-transaxle mounting bolt.
  10.  
  11. Install the A/C compressor in the mounting bracket.
  12.  
  13. Secure the torque converter-to-flywheel bolts, then tighten to 46 ft. lbs. (62 Nm).
  14.  
  15. Secure the engine mount-to-frame nuts, then tighten them to 33 ft. lbs. (45 Nm).
  16.  
  17. Connect and install the starter, then tighten the mounting bolts to 33 ft. lbs. (45 Nm).
  18.  
  19. Connect the exhaust pipe to the exhaust manifold, then tighten the mounting bolts to 22 ft. lbs. (30 Nm).
  20.  
  21. Attach the right inner fender well splash shield.
  22.  
  23. Install the tire and wheel assembly, then lower the vehicle.
  24.  
  25. Tighten the lug nuts to 100 ft. lbs. (136 Nm).
  26.  
  27. Install the remainder of the engine-to-transaxle bolts, then tighten all the bolts to 37 ft. lbs. (50 Nm).
  28.  
  29. Insert the transaxle fill tube.
  30.  
  31. Connect the electrical harness to the rear of the engine.
  32.  
  33. Install the power steering pump onto it's mounting bracket.
  34.  
  35. Connect the engine harness.
  36.  
  37. Attach the power steering pump onto the bracket.
  38.  
  39. Install the torque strut, then tighten the mounting bolts to 41 ft. lbs. (51 Nm).
  40.  
  41. Attach the heater hoses to the intake manifold and the water pump.
  42.  
  43. Attach the upper and lower radiator hoses.
  44.  
  45. Connect any vacuum hoses disconnected at removal.
  46.  
  47. Connect the fuel lines to the throttle body and the fuel line brackets.
  48.  
  49. Install the throttle cable bracket on the intake manifold and rocker arm cover, then connect the control cables to the throttle body.
  50.  
  51. Install the air cleaner and air inlet duct work.
  52.  
  53. Connect the hood hydraulic shock to the cowl panel.
  54.  
  55. Refill the cooling system and engine oil if needed.
  56.  
  57. Connect the negative battery cable.
  58.  
  59. Start the vehicle, top the cooling system as it warms up.
  60.  
  61. Check for leaks.
  62.  

2.5L Engine With Manual Transaxle

CAUTION
The fuel system is under pressure and must have the pressure relieved prior to disconnecting the fuel lines. Failure to properly bleed the system can lead to personal injury.

  1. Relive the fuel pressure.
  2.  
  3. Disconnect the battery cables at the battery.
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Remove the front mount-to-cradle nuts.
  8.  
  9. Remove the forward exhaust pipe.
  10.  
  11. Remove the starter assembly, make sure the wires are attached, then swing to the side.
  12.  
  13. Remove the flywheel inspection cover.
  14.  
  15. Lower the car.
  16.  
  17. Remove the air cleaner assembly.
  18.  
  19. Remove all the bell housing bolts.
  20.  
  21. Remove the forward torque rod from the engine and the core support.
  22.  
  23. If equipped with air conditioning, remove the air conditioning belt and compressor, then put to the side.
  24.  
  25. Unfasten the emission hoses at the canister.
  26.  
  27. Remove the power steering hoses (if so equipped).
  28.  
  29. Detach the vacuum hoses and the electrical harness at solenoid.
  30.  
  31. Remove the heater blower motor.
  32.  
  33. Disconnect the throttle cable.
  34.  
  35. Drain the heater hose.
  36.  
  37. Disconnect the heater hose.
  38.  
  39. Disconnect the radiator hoses.
  40.  
  41. Disconnect engine harness at the bulkhead.
  42.  
  43. With an engine lifting tool, hoist the engine (remove heater hose at intake manifold, then disconnect the fuel line).
  44.  

To install:
  1. Lower the engine into the engine compartment.
  2.  
  3. Connect engine the harness at the bulkhead.
  4.  
  5. Install the radiator hoses.
  6.  
  7. Connect the heater hoses.
  8.  
  9. Attach the throttle cable.
  10.  
  11. Install the heater blower motor.
  12.  
  13. Install the vacuum hoses and electrical connectors at the solenoid.
  14.  
  15. Connect the power steering hose.
  16.  
  17. Install the emission hoses at the canister.
  18.  
  19. Install the air conditioning compressor and belt.
  20.  
  21. Install the forward torque reaction rod to the engine and core support.
  22.  
  23. Secure all of the bell housing bolts.
  24.  
  25. Install the air cleaner.
  26.  
  27. Raise and support the vehicle.
  28.  
  29. Install the flywheel inspection cover.
  30.  
  31. Install the starter assembly.
  32.  
  33. Connect the forward exhaust pipe.
  34.  
  35. Install the front mount-to-cradle nuts.
  36.  
  37. Lower the vehicle and install the battery.
  38.  
  39. Fill the engine oil and cooling system, start the engine, then top off the fluids.
  40.  

2.5L Engine With Automatic Transaxle

CAUTION
The fuel system is under pressure and must have the pressure relieved prior to disconnecting the fuel lines. Failure to properly bleed the system can lead to personal injury.

  1. Relive the fuel pressure.
  2.  
  3. Disconnect the battery cables at battery.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove the air cleaner and pre-heat tube.
  8.  
  9. Disconnect the engine harness.
  10.  
  11. Disconnect and tag all of the external vacuum hoses.
  12.  
  13. Remove the throttle and transaxle linkage at E.F.I. assembly and the intake manifold.
  14.  
  15. Remove the upper radiator hose.
  16.  
  17. If equipped with air conditioning, remove the air conditioning compressor from it's mounting brackets, then set aside. Do not disconnect the hoses.
  18.  
  19. Unsecure and remove the front engine strut assembly.
  20.  
  21. Disconnect the heater hose at intake manifold.
  22.  
  23. Remove the transaxle-to-engine bolts, make sure to leave the upper two bolts in place.
  24.  
  25. Remove the front mount-to-cradle nuts.
  26.  
  27. Disconnect and drop the forward exhaust pipe.
  28.  
  29. Remove the flywheel inspection cover, then remove the starter motor.
  30.  
  31. Remove the torque converter-to-flywheel bolts.
  32.  
  33. Remove the power steering pump and bracket, then move aside.
  34.  
  35. Detach the heater hose and lower radiator hose.
  36.  
  37. Remove the two rear transaxle support bracket bolts.
  38.  
  39. Remove the fuel supply line at the fuel filter.
  40.  
  41. Using a floor jack, and a block of wood placed under the transaxle, raise engine and transaxle until the engine front mount studs clear the cradle.
  42.  
  43. Connect the engine lift equipment and put tension on engine.
  44.  
  45. Remove the two remaining transaxle bolts.
  46.  
  47. Slide the engine forwards and lift it from the vehicle.
  48.  

To install:
  1. Lower the engine into the vehicle. Do not completely lower the engine while the jack is supporting the transaxle.
  2.  
  3. Install the two transaxle bolts.
  4.  
  5. Remove the floor jack and lower the engine completely into the vehicle.
  6.  
  7. Connect the fuel supply line and install the filter.
  8.  
  9. Install the two transaxle rear support bracket bolts.
  10.  
  11. Install the heater and lower radiator hoses.
  12.  
  13. Connect the power steering bracket and pump.
  14.  
  15. Install the torque converter-to-flywheel bolts.
  16.  
  17. Install the starter motor and the flywheel inspection cover.
  18.  
  19. Connect the forward exhaust pipe.
  20.  
  21. Install the front mount-to-cradle nuts.
  22.  
  23. Install the transaxle to engine bolts.
  24.  
  25. Connect the heater hose at intake manifold.
  26.  
  27. Install the front engine strut assembly.
  28.  
  29. Install the air conditioning compressor mounting brackets and the compressor.
  30.  
  31. Install the upper radiator hose.
  32.  
  33. Connect the throttle and transaxle linkage at the E.F.I. assembly and intake manifold.
  34.  
  35. Connect all the external vacuum hose connections.
  36.  
  37. Connect the engine harness.
  38.  
  39. Install the air cleaner and pre-heat tube.
  40.  
  41. Fill the cooling system.
  42.  
  43. Connect battery cables at battery.
  44.  
  45. Start the engine, top the cooling system, check for leaks.
  46.  

2.8L Engine With Manual Transaxle

CAUTION
The fuel system is under pressure and must have the pressure relieved prior to disconnecting the fuel lines. Failure to properly bleed the system can lead to personal injury.

  1. Relieve the fuel pressure.
  2.  
  3. Disconnect the cables from the battery.
  4.  
  5. Remove the air cleaner assembly.
  6.  
  7. Drain the cooling system.
  8.  
  9. Disconnect and tag the vacuum hoses to all of the non-engine mounted components.
  10.  
  11. Disconnect the accelerator linkage from the carburetor.
  12.  
  13. Disconnect the engine harness from the ECM/PCM, then pull the connector through the front of the dash.
  14.  
  15. Disconnect the radiator hoses from radiator.
  16.  
  17. Disconnect the heater hoses from the engine.
  18.  
  19. If equipped, remove the power steering pump and bracket assembly from the engine.
  20.  
  21. Disconnect the clutch cable from the transaxle.
  22.  
  23. Disconnect the shift linkage from the transaxle shift levers. Remove the cables from the transaxle bosses.
  24.  
  25. Disconnect the speedometer cable from the transaxle.
  26.  
  27. Raise and support the vehicle on jackstands.
  28.  
  29. Remove the exhaust crossover pipe.
  30.  
  31. Remove all but one of the transaxle-to-engine retaining bolts.
  32.  
  33. Remove the side and crossmember assembly.
  34.  
  35. Disconnect the exhaust pipe.
  36.  
  37. Remove all the powertrain mount-to-cradle attachments.
  38.  
  39. Disconnect the engine harness from the junction block at the left side of the dash.
  40.  
  41. Lower the vehicle. If equipped with MFI, disconnect the throttle, T.V. and cruise control cables at the throttle body.
  42.  
  43. Install the engine support fixture. Raise the engine until the weight is relieved from the mount assembled.
  44.  
  45. Lower the left side of the engine/transaxle assembly.
  46.  
  47. Place a jack under the transaxle.
  48.  
  49. Remove the final transaxle-to-engine attaching bolt, then separate the transaxle from the engine and lower.
  50.  
  51. Lower the vehicle.
  52.  
  53. Install the engine lifting device.
  54.  
  55. If equipped with air conditioning, remove the compressor from the mounting bracket and swing aside.
  56.  
  57. Disconnect the forward strut bracket from the radiator support. Swing aside.
  58.  
  59. Lift the engine out of the vehicle.
  60.  

To install:
  1. Lower the engine into the vehicle.
  2.  
  3. Connect the forward strut bracket to radiator support.
  4.  
  5. Install the air conditioning compressor and mounting bracket.
  6.  
  7. Raise the vehicle and place the transaxle jack under the transaxle.
  8.  
  9. Raise the transaxle flush with the engine, then install the engine-to-transaxle attaching bolts.
  10.  
  11. Remove the transaxle jack and lower the vehicle just enough to install the engine support fixture.
  12.  
  13. Raise the engine until the weight is relieved from the mount assemblies.
  14.  
  15. Connect all of the powertrain mount-to-cradle attachments.
  16.  
  17. Connect the exhaust pipe.
  18.  
  19. Install the side and crossmember assembly. Connect the engine harness to the junction block at the left side of the dash.
  20.  
  21. Install all remaining transaxle-to-engine retaining bolts.
  22.  
  23. Install the exhaust crossover.
  24.  
  25. Remove the engine support fixture.
  26.  
  27. Lower the vehicle.
  28.  
  29. Connect the speedometer cable to the transaxle.
  30.  
  31. Install the cables to the transaxle bosses.
  32.  
  33. Connect the transaxle shift linkage.
  34.  
  35. Connect the clutch cable.
  36.  
  37. Install the power steering bracket and pump assembly.
  38.  
  39. Connect the heater hoses to the engine.
  40.  
  41. Install the radiator hoses to the radiator.
  42.  
  43. Feed the engine harness through the front of the dash, then attach it to the ECM/PCM.
  44.  
  45. Connect the throttle, T.V. and the cruise control cables at the throttle body.
  46.  
  47. Connect the accelerator linkage to the carburetor.
  48.  
  49. Connect vacuum hosing to all non-engine mounted components.
  50.  
  51. Fill the cooling system.
  52.  
  53. Install the air cleaner.
  54.  
  55. Connect the battery cables.
  56.  
  57. Start the engine, top off the cooling system, check for leaks.
  58.  

2.8L Engine With Automatic Transaxle

CAUTION
The fuel system is under pressure and must have the pressure relieved prior to disconnecting the fuel lines. Failure to properly bleed the system can lead to personal injury.

  1. Relieve the fuel pressure.
  2.  
  3. Disconnect the battery cables from the battery.
  4.  
  5. Remove the air cleaner.
  6.  
  7. Drain the cooling system.
  8.  
  9. Disconnect and tag the vacuum hoses to all non-engine mounted components.
  10.  
  11. Disconnect the detent cable from the carburetor lever.
  12.  
  13. Disconnect the accelerator linkage. If equipped with MFI, disconnect the throttle at the T.V. and the cruise control cables at the throttle body.
  14.  
  15. Disconnect the engine harness from the ECM/PCM, then pull the connector through the front of the dash, then disconnect it from the junction block at the left side of the dash.
  16.  
  17. Disconnect the ground strap from the engine at the engine forward strut.
  18.  
  19. Remove the radiator hoses from radiator.
  20.  
  21. Disconnect the heater hoses from engine.
  22.  
  23. Remove the power steering pump and bracket assembly from the engine, if equipped.
  24.  
  25. Raise and support the vehicle.
  26.  
  27. Disconnect the exhaust pipe.
  28.  
  29. Disconnect the fuel lines at their rubber hose connections at the right side of the engine.
  30.  
  31. Remove the engine front mount-to-cradle retaining nuts (right side of vehicle).
  32.  
  33. Disconnect the battery cables from the engine (starter and transaxle housing bolt).
  34.  
  35. Remove the flex plate cover, then disconnect the torque converter from the flex plate.
  36.  
  37. Remove the transaxle case-to-cylinder case support bracket bolts.
  38.  
  39. Lower the vehicle. Place a support under the transaxle rear extension.
  40.  
  41. Remove the engine strut bracket from the radiator support and swing rearward.
  42.  
  43. Remove the exhaust crossover pipe.
  44.  
  45. Remove the transaxle-to-cylinder case retaining bolts. Make note of ground stud location.
  46.  
  47. If air conditioning equipped, remove the compressor from the mounting bracket and lay aside.
  48.  
  49. Install a lift fixture to the engine, then remove engine from the vehicle.
  50.  

To install:
  1. Lower the engine into the vehicle.
  2.  
  3. Install the compressor mounting bracket and the compressor.
  4.  
  5. Install the transaxle to cylinder case retaining bolts and the ground stud.
  6.  
  7. Install the exhaust crossover pipe.
  8.  
  9. Install the engine stud bracket to the radiator support.
  10.  
  11. Raise the vehicle and remove the support from the transaxle rear extension.
  12.  
  13. Install the transaxle case to cylinder case support bracket bolts.
  14.  
  15. Connect the torque converter to the flex plate and install the flex plate cover.
  16.  
  17. Connect the battery cables to the engine (starter and transaxle housing bolt).
  18.  
  19. Install the engine front mount to cradle retaining nuts (right side of vehicle).
  20.  
  21. Connect the fuel lines at the rubber hose connections at the right side of the engine.
  22.  
  23. Connect the exhaust pipe.
  24.  
  25. Lower the vehicle.
  26.  
  27. Install the power steering pump and bracket assembly to the engine.
  28.  
  29. Connect the heater hoses to the engine.
  30.  
  31. Connect the radiator hoses to the radiator.
  32.  
  33. Attach the ground strap to the engine at the engine forward strut.
  34.  
  35. Connect the engine harness connector to the junction block at the left side of the dash then push the connector through the front of the dash and connect it to the ECM/PCM.
  36.  
  37. Attach the accelerator linkage. If equipped with MFI, connect the throttle at the T.V. and the cruise control cables at the throttle body.
  38.  
  39. Connect the detent cable from the carburetor lever.
  40.  
  41. Connect the vacuum hosing to all non-engine mounted components.
  42.  
  43. Fill the cooling system.
  44.  
  45. Install the air cleaner.
  46.  
  47. Connect battery cables.
  48.  
  49. Start the engine, top off the cooling system, then check for leaks.
  50.  

3.0L Engine

CAUTION
The fuel system is under pressure and must have the pressure relieved prior to disconnecting the fuel lines. Failure to properly bleed the system can lead to personal injury.

  1. Relieve the fuel pressure.
  2.  
  3. Disconnect the battery cables from the battery.
  4.  
  5. Remove the air cleaner.
  6.  
  7. Drain the cooling system.
  8.  
  9. Disconnect and tag the vacuum hoses to all non-engine mounted components.
  10.  
  11. Remove the detent cable from the carburetor lever.
  12.  
  13. Unsecure the accelerator linkage.
  14.  
  15. Disconnect the engine harness.
  16.  
  17. Loosen and remove the ground strap from the engine at the engine forward strut.
  18.  
  19. Disconnect the radiator hoses from radiator.
  20.  
  21. Disconnect all heater hoses from engine.
  22.  
  23. Remove the power steering pump and bracket assembly from the engine.
  24.  
  25. Raise and support the vehicle.
  26.  
  27. Disassemble the exhaust pipe at the manifold.
  28.  
  29. Disconnect all fuel lines at the rubber hose connections.
  30.  
  31. Remove the engine front mount-to-cradle retaining nuts (right side of vehicle).
  32.  
  33. Disconnect the battery cables from engine (starter and transaxle housing bolt).
  34.  
  35. Remove the flex plate cover, then disconnect the torque converter from the flex plate.
  36.  
  37. Remove the transaxle case-to-cylinder case support bracket bolts.
  38.  
  39. Lower the vehicle. Place a support under the transaxle rear extension.
  40.  
  41. Remove the engine strut bracket from the radiator support and swing rearwards.
  42.  
  43. Remove transaxle to cylinder case retaining bolts. Make note of ground stud location.
  44.  
  45. If air conditioning equipped, remove the compressor from the mounting bracket and lay aside.
  46.  
  47. Install a lift fixture to the engine.
  48.  
  49. Remove the engine from the vehicle.
  50.  

To install:
  1. Lower the engine into the vehicle.
  2.  
  3. Attach the compressor mounting bracket and the compressor to the vehicle.
  4.  
  5. Install the transaxle-to-cylinder case retaining bolts and the ground stud.
  6.  
  7. Install the exhaust crossover pipe.
  8.  
  9. Install the engine stud bracket to the radiator support.
  10.  
  11. Raise the vehicle and remove the support from the transaxle rear extension.
  12.  
  13. Install the transaxle case to cylinder case support bracket bolts.
  14.  
  15. Connect the torque converter to the flex plate and install the flex plate cover.
  16.  
  17. Connect the battery cables to the engine (starter and transaxle housing bolt).
  18.  
  19. Install the engine front mount to cradle retaining nuts (right side of vehicle).
  20.  
  21. Connect fuel lines at rubber hose connections at right side of engine.
  22.  
  23. Connect exhaust pipe.
  24.  
  25. Lower the vehicle.
  26.  
  27. Install the power steering pump and bracket assembly to the engine.
  28.  
  29. Connect the heater hoses to the engine.
  30.  
  31. Connect the radiator hoses to the radiator.
  32.  
  33. Assemble the ground strap to the engine at the engine forward strut.
  34.  
  35. Connect the engine harness connector to the junction block at the left side of the dash then push the connector through the front of the dash and connect it to the ECM/PCM.
  36.  
  37. Connect the accelerator linkage.
  38.  
  39. Connect detent cable from carburetor lever.
  40.  
  41. Connect vacuum hosing to all non-engine mounted components.
  42.  
  43. Fill the cooling system.
  44.  
  45. Install the air cleaner.
  46.  
  47. Connect battery cables.
  48.  

3.1L Engine (VIN T)

CAUTION
The fuel system is under pressure and must have the pressure relieved prior to disconnecting the fuel lines. Failure to properly bleed the system can lead to personal injury.

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable. Scribe reference marks at the hood supports and remove the hood. Install covers on both fenders.
  4.  
  5. Remove the airflow tube at the air cleaner and throttle valve.
  6.  
  7. Drain the cooling system.
  8.  
  9. Disconnect and tag all vacuum hoses from all non-engine mounted components.
  10.  
  11. Disassemble the accelerator linkage and TV cable, then disconnect the cruise control cable, if equipped.
  12.  
  13. Disconnect the engine harness connector from the ECM/PCM and pull the connector through the front of dash. Disconnect the engine harness from the junction block at the dash panel.
  14.  
  15. Remove the engine strut bracket from the radiator support and position aside, as required.
  16.  
  17. Disconnect the radiator hoses from radiator and heater hoses from engine. Disconnect and plug the transaxle cooler lines.
  18.  
  19. Remove the serpentine belt cover and belt.
  20.  
  21. On vehicles with the air conditioning compressor mounted on the upper portion of the engine, remove the AIR pump and bracket. Then, remove the air conditioning compressor from the mounting bracket and position aside.
  22.  
  23. If equipped, remove power steering pump from engine and set it aside. Disconnect and cap any power steering lines.
  24.  
  25. Disconnect and plug the fuel lines.
  26.  
  27. Disconnect the EGR at the exhaust, as required.
  28.  
  29. Raise and safely support the vehicle.
  30.  
  31. On vehicles with the air conditioning compressor mounted on the lower portion of the engine, remove the air conditioning compressor from the engine. Do not discharge the air conditioning system.
  32.  
  33. Remove the engine front mount-to-cradle and mount-to-engine bracket retaining nuts, as required.
  34.  
  35. Disconnect and tag all electrical wiring at the starter. Remove the starter retaining bolts and remove the starter.
  36.  
  37. If equipped with automatic transaxle, remove the transaxle inspection cover and disconnect the torque converter from the flexplate.
  38.  
  39. Disconnect the exhaust pipe.
  40.  
  41. Remove the 1 transaxle-to-engine bolt from the back side of the engine.
  42.  
  43. Disconnect the power steering cut-off switch, if equipped.
  44.  
  45. Lower the vehicle.
  46.  
  47. Remove the exhaust crossover pipe.
  48.  
  49. Remove the remaining transaxle-to-engine bolts.
  50.  
  51. Support the transaxle by positioning a floor jack and a block of wood under the transaxle. Install an engine lift tool and remove the engine from the vehicle.
  52.  

To install:
  1. Position the engine in the vehicle while aligning the transaxle. Install the transaxle-to-engine bolts.
  2.  
  3. Position the front engine mount studs in the cradle and engine bracket.
  4.  
  5. Remove the engine lift tool. Raise and support the vehicle safely.
  6.  
  7. Install the engine mount retaining nuts.
  8.  
  9. If equipped, connect the power steering cut-off switch.
  10.  
  11. Install the 1 transaxle-to-engine bolt from the back side of the engine.
  12.  
  13. Connect the exhaust pipe.
  14.  
  15. If equipped with automatic transaxle, connect the torque converter to the flexplate and install the transaxle inspection cover.
  16.  
  17. Install the starter and retaining bolts. Connect the starter electrical connectors.
  18.  
  19. Install the engine front mount-to-cradle and mount-to-engine bracket retaining nuts.
  20.  
  21. On vehicles with the air conditioning compressor mounted on the lower portion of the engine, install the air conditioning compressor.
  22.  
  23. Lower the vehicle.
  24.  
  25. Connect the EGR at the exhaust, if removed.
  26.  
  27. Connect the fuel lines.
  28.  
  29. If equipped, install power steering pump.
  30.  
  31. On vehicles with the air conditioning compressor mounted on the upper portion of the engine, install the air conditioner compressor. Install the AIR pump and bracket.
  32.  
  33. Install the serpentine belt cover and belt.
  34.  
  35. Connect the radiator and heater hoses. Connect the transaxle cooler lines.
  36.  
  37. Install the engine strut bracket to the radiator support.
  38.  
  39. Connect the engine harness connector to the ECM/PCM.
  40.  
  41. Connect the accelerator linkage and TV cable. Connect the cruise control cable, if equipped.
  42.  
  43. Connect vacuum hoses to all non-engine mounted components.
  44.  
  45. Install the airflow tube at the air cleaner and throttle valve.
  46.  
  47. Install the hood using the reference marks made upon removal.
  48.  
  49. Connect the negative battery cable.
  50.  
  51. Fill cooling system and check for leaks. Start the engine and allow to come to normal operating temperature. Check for leaks and refill the cooling system.
  52.  

3.1L Engine (VIN M)

CAUTION
Fuel injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the top half of the air cleaner assembly and the throttle body inlet duct.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove the upper and lower radiator hoses.
  10.  
  11. Disconnect the coolant inlet line from the coolant surge tank.
  12.  
  13. Disconnect and tag the vacuum hoses from the EVAP canister purge valve, vacuum modulator and power brake booster.
  14.  
  15. Disconnect the heater outlet hose from the water pump.
  16.  
  17. Remove the serpentine drive belt.
  18.  
  19. Disconnect the control cables from the throttle body lever and intake manifold bracket and position the cables out of the way.
  20.  
  21. Disconnect the following electrical connectors from their related components:

    Ignition assembly
     
    Oxygen sensor
     
    Fuel injectors
     
    Idle Air Control (IAC) valve
     
    Throttle Position Sensor (TPS)
     
    Coolant sensor
     
    Park neutral switch
     
    TCC solenoid
     
    Shift solenoid
     
    EGR valve
     
    Transaxle ground
     

  22.  
  23. Remove the alternator.
  24.  
  25. Disconnect and cap the power steering lines from the power steering pump.
  26.  
  27. Disconnect and cap the fuel lines from the fuel rail.
  28.  
  29. Remove the cooling fan assembly.
  30.  
  31. Disconnect the shift control cable from the transaxle shift lever and cable bracket.
  32.  
  33. Detach the transaxle vent tube from the transaxle.
  34.  
  35. Disconnect the vacuum hose from the vacuum reservoir.
  36.  
  37. Install an engine support fixture, J-28467-A, or the equivalent.
  38.  
  39. Loosen, but do not remove the top 2 A/C compressor mounting bolts.
  40.  
  41. Raise and safely support the vehicle.
  42.  
  43. Remove the front tire and wheel assemblies.
  44.  
  45. Remove the right and left inner fender splash shields.
  46.  
  47. Remove the engine mount strut.
  48.  
  49. Disconnect the ABS sensor wires from the wheel sensors and suspension member supports, if equipped.
  50.  
  51. Remove the cotter pins and castle nuts from the lower ball joints. Using a suitable tool, separate the lower ball joints from the steering knuckles.
  52.  
  53. Remove the lower suspension support assemblies with the lower control arms attached.
  54.  
  55. Disconnect the halfshafts from the transaxle and support out of the way.
  56.  
  57. Remove the oil filter and oil filter adapter.
  58.  
  59. Remove the flywheel cover.
  60.  
  61. Remove the starter.
  62.  
  63. Disconnect the following electrical connectors from their related components:

    Knock sensor
     
    Front crankshaft position sensor
     
    Side crankshaft position sensor
     
    Oil level sensor
     
    Vehicle speed sensor
     
    Transaxle ground
     

  64.  
  65. Disconnect the heater hoses from the heater core.
  66.  
  67. Remove the A/C compressor lower mounting bolts and remove the compressor from the mounting bracket and position aside. DO NOT disconnect the refrigerant lines from the compressor or allow the lines top support the weight of the compressor.
  68.  
  69. Remove the vacuum reservoir tank.
  70.  
  71. Disconnect the exhaust pipe from the exhaust manifold and position the pipe aside.
  72.  
  73. Remove the engine mount strut bracket from the engine.
  74.  
  75. Disconnect the transaxle cooler lines from the radiator.
  76.  
  77. Remove the transaxle oil fill tube.
  78.  
  79. Lower the vehicle until the powertrain assembly is resting on a suitable engine table.
  80.  
  81. Unbolt the transaxle mount-to-body bolts.
  82.  
  83. Remove the intermediate bracket from the right engine mount.
  84.  
  85. Remove the engine support fixture.
  86.  
  87. Raise the vehicle leaving the powertrain assembly on the engine table.
  88.  
  89. Separate the engine and transaxle assemblies.
  90.  

To install:
  1. Connect the transaxle to the engine and tighten the mounting bolts to 55 ft. lbs. (75 Nm).
  2.  
  3. Position the powertrain assembly under the vehicle and lower the vehicle into position.
  4.  
  5. Loosely install the serpentine belt.
  6.  
  7. Install the intermediate bracket to the right side engine mount.
  8.  
  9. Install the transaxle-to-body bolts.
  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Install the transaxle fill tube.
  14.  
  15. Connect the transaxle cooler lines to the radiator.
  16.  
  17. Install the engine strut bracket to the engine and tighten the mounting bolts to 44 ft. lbs. (60 Nm).
  18.  
  19. Connect the exhaust pipe to the exhaust manifold and tighten the mounting bolts to 18 ft. lbs. (25 Nm).
  20.  
  21. Install the vacuum reserve tank.
  22.  
  23. Install the A/C compressor in the mounting bracket. Install the upper bolts loosely and tighten the lower bolts.
  24.  
  25. Connect the heater hoses to the heater core.
  26.  
  27. Connect the following electrical connectors to their related components:

    Knock sensor
     
    Front crankshaft position sensor
     
    Side crankshaft position sensor
     
    Oil level sensor
     
    Vehicle speed sensor
     
    Transaxle ground
     

  28.  
  29. Attach the starter to the engine.
  30.  
  31. Install the flywheel cover.
  32.  
  33. Install the oil filter adapter and after coating the oil filter seal with clean engine oil, install the oil filter.
  34.  
  35. Connect the drive axles to the transaxle.
  36.  
  37. Install the suspension support assemblies and lower control arms.
  38.  
  39. Connect the lower ball joints to the steering knuckles and tighten the castle nuts to 41 ft. lbs. (55 Nm).
  40.  
  41. Connect the ABS sensor wires to the wheel sensors and suspension support wire clips.
  42.  
  43. Install the engine mount strut.
  44.  
  45. Reinstall the left and right inner fender splash shields.
  46.  
  47. Install the right front tire and wheel assemblies.
  48.  
  49. Lower the vehicle.
  50.  
  51. Tighten the upper A/C compressor mounting bolts.
  52.  
  53. Remove the engine support fixture.
  54.  
  55. Connect the vacuum hose to the reservoir.
  56.  
  57. Connect the transaxle vent hose to the transaxle.
  58.  
  59. Connect the shift cable linkage to the cable bracket and shift lever on the transaxle.
  60.  
  61. Install the cooling fan assembly.
  62.  
  63. Connect the fuel lines to the fuel rail.
  64.  
  65. Connect the power steering lines to the power steering pump.
  66.  
  67. Install the alternator.
  68.  
  69. Connect the following electrical connectors to their related components:

    Ignition assembly
     
    Oxygen sensor
     
    Fuel injectors
     
    Idle Air Control (IAC) valve
     
    Throttle Position Sensor (TPS)
     
    Coolant sensor
     
    Park neutral switch
     
    TCC solenoid
     
    Shift solenoid
     
    EGR valve
     
    Transaxle ground
     

  70.  
  71. Connect the control cables to the throttle body lever and cable bracket.
  72.  
  73. Install the serpentine belt.
  74.  
  75. Connect the heater outlet hose to the water pump.
  76.  
  77. Connect the vacuum hoses to the power brake booster, vacuum modulator and EVAP purge solenoid.
  78.  
  79. Connect the coolant inlet line to the surge tank.
  80.  
  81. Install the upper and lower radiator hoses.
  82.  
  83. Install the top half of the air cleaner assembly and the throttle body air inlet duct.
  84.  
  85. Connect the negative battery cable.
  86.  
  87. Check and fill all the engine fluids as necessary.
  88.  
  89. Start the vehicle and bleed the power steering system.
  90.  

3.3L Engine

CAUTION
The fuel system is under pressure and must have the pressure relieved prior to disconnecting the fuel lines. Failure to properly bleed the system can lead to personal injury.

  1. Disconnect the negative battery cable. Scribe reference marks at the hood supports and remove the hood. Install covers on both fenders.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Drain the cooling system. Disconnect the radiator and heater hoses. Disconnect and plug the transaxle cooler lines.
  8.  
  9. Remove the upper engine strut and engine cooling fan.
  10.  
  11. Remove the intake duct from the throttle body. Disconnect and tag the vacuum hoses from all non-engine mounted components. Disconnect all electrical connections.
  12.  
  13. Remove the cable bracket and cables from the throttle body.
  14.  
  15. Remove the serpentine belt. If equipped, remove the power steering pump and locate to the side.
  16.  
  17. Unfasten the upper transaxle-to-engine retaining bolts.
  18.  
  19. Raise and support the vehicle safely.
  20.  
  21. Remove the air conditioning compressor and locate to the side.
  22.  
  23. Remove the engine mount-to-frame nuts, flywheel dust cover and flywheel-to-converter bolts.
  24.  
  25. Remove the lower engine-to-transaxle bolts; 1 bolt is located behind the transaxle case and engine block.
  26.  
  27. Lower the vehicle. Install an engine lift tool and remove the engine from the vehicle.
  28.  

To install:
  1. Install the engine in the engine compartment. Install the upper engine-to-transaxle bolts. Remove the engine lift tool.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Install the lower engine-to-transaxle bolts; 1 bolt is located behind the transaxle case and engine block.
  6.  
  7. Install the flywheel-to-converter bolts, flywheel dust cover and engine mount-to-frame nuts.
  8.  
  9. Install the air conditioning compressor.
  10.  
  11. Lower the vehicle.
  12.  
  13. If equipped, install the power steering pump. Install the serpentine belt.
  14.  
  15. Install the cable bracket and cables to the throttle body.
  16.  
  17. Install the intake duct to the throttle body. Connect vacuum hoses to all non-engine mounted components. Connect all electrical connections.
  18.  
  19. Install the upper engine strut and engine cooling fan.
  20.  
  21. Connect the radiator and heater hoses. Connect the transaxle cooler lines.
  22.  
  23. Install the hood.
  24.  
  25. Connect the negative battery cable.
  26.  
  27. Fill cooling system and check for leaks. Start the engine and allow to come to normal operating temperature. Recheck for leaks and fill the cooling system.
  28.  

3.8L Engine

CAUTION
The fuel system is under pressure and must have the pressure relieved prior to disconnecting the fuel lines. Failure to properly bleed the system can lead to personal injury.

  1. Relive the fuel pressure.
  2.  
  3. Disconnect the negative battery cable. Scribe reference marks at the hood supports and remove the hood. Install covers on both fenders.
  4.  
  5. Remove the air cleaner assembly and drain the cooling system.
  6.  
  7. Disconnect and tag the vacuum hoses to all non-engine mounted components.
  8.  
  9. Disconnect the detent cable and accelerator linkage.
  10.  
  11. Disconnect the engine electrical harness and ground strap.
  12.  
  13. Disconnect the heater hoses from the engine and radiator hoses from the radiator. Disconnect the transaxle cooler lines, if equipped.
  14.  
  15. If equipped, remove the power steering pump and bracket assembly.
  16.  
  17. Raise and safely support the vehicle.
  18.  
  19. Disconnect the exhaust pipe from the manifold.
  20.  
  21. Disconnect the fuel lines.
  22.  
  23. Remove the engine front mount-to-cradle retaining nuts.
  24.  
  25. Disconnect and tag all electrical wiring at the starter. Remove the starter retaining bolts and remove the starter.
  26.  
  27. Remove the flexplate cover and disconnect the flexplate from the torque converter.
  28.  
  29. Remove the retaining bolts from the transaxle rear support bracket.
  30.  
  31. Lower the vehicle and place a support under the transaxle rear extension.
  32.  
  33. Remove the engine strut bracket from the radiator support and position aside.
  34.  
  35. Remove the transaxle-to-engine retaining bolts.
  36.  
  37. If equipped with air conditioning, remove the air conditioning compressor from the mounting bracket and lay aside.
  38.  
  39. Install an engine lift tool and remove the engine from the vehicle.
  40.  

To install:
  1. Position the engine in the vehicle and align the engine front mount studs. Align the transaxle and install the transaxle-to-engine retaining bolts.
  2.  
  3. Remove the engine lift tool.
  4.  
  5. If equipped, install the air conditioning compressor to the mounting bracket.
  6.  
  7. Raise and safely support the vehicle. Install the retaining bolts to the transaxle rear support bracket.
  8.  
  9. Connect the flexplate to the torque converter and install the flexplate cover.
  10.  
  11. Install the starter and retaining bolts. Connect the starter electrical connectors.
  12.  
  13. Install the engine front mount-to-cradle retaining nuts.
  14.  
  15. Connect the fuel lines.
  16.  
  17. Connect the exhaust pipe to the manifold.
  18.  
  19. Lower the vehicle.
  20.  
  21. If equipped, install the power steering bracket assembly and pump.
  22.  
  23. Connect the heater and radiator hoses. Connect the transaxle cooler lines, if equipped.
  24.  
  25. Connect the engine electrical harness and ground strap.
  26.  
  27. Connect the detent cable and accelerator linkage.
  28.  
  29. Connect vacuum hoses to all non-engine mounted components.
  30.  
  31. Install the air cleaner assembly.
  32.  
  33. Install the hood.
  34.  
  35. Connect the negative battery cable.
  36.  
  37. Fill cooling system and check for leaks. Start the engine and allow to come to normal operating temperature. Check for leaks and refill the cooling system.
  38.  

4.3L Diesel Engine
  1. Drain the cooling system. Remove the serpentine drive belt (and vacuum pump drive belt, if air conditioning equipped).
  2.  
  3. Remove the air cleaner and install cover J-26996.
  4.  
  5. Disconnect the negative battery cable(s) at the batteries, and the ground wires at the inner fender panel. Disconnect the engine ground strap, at the rear (right) head to cowl.
  6.  
  7. Raise and support the vehicle.
  8.  
  9. Remove the flywheel cover.
  10.  
  11. Remove the flywheel-to-torque converter bolts.
  12.  
  13. Disconnect the exhaust pipe from the rear exhaust manifold.
  14.  
  15. Remove the engine-to-transaxle brace.
  16.  
  17. Remove the engine mount-to-cradle retaining nuts and washers.
  18.  
  19. Disconnect the leads to the starter motor, the No. 2 cylinder glow plug, and the battery ground cable at the transaxle-to-engine bolt.
  20.  
  21. Disconnect the lower oil cooler hose and cap the openings.
  22.  
  23. Remove the accessible power steering pump bracket fasteners.
  24.  
  25. Lower the car.
  26.  
  27. Remove the remaining power steering pump bracket/brace fasteners and lower the power steering pump with hoses out of the way.
  28.  
  29. Remove the heater water return pipe.
  30.  
  31. Disconnect all of the remaining glow plug leads, at the glow plugs.
  32.  
  33. Disconnect all other leads at the engine, disconnect the engine harness at the cowl connector and body mounted relays, then position the engine harness aside.
  34.  
  35. If air conditioning equipped, disconnect the compressor with brackets and lines attached, then position them aside.
  36.  
  37. Disconnect the fuel and vacuum hoses, cap all fuel line openings.
  38.  
  39. Disconnect the throttle and T.V. cables at the injection pump, and the cable bracket. Position all cables aside.
  40.  
  41. Disconnect the upper oil cooler hose and cap the openings.
  42.  
  43. Remove the exhaust crossover pipe heat shield.
  44.  
  45. Disconnect and move aside the transaxle filler tube.
  46.  
  47. Remove the exhaust crossover pipe.
  48.  
  49. Remove the engine mounting strut and strut brackets.
  50.  
  51. Install a suitable engine lifting device. Make certain that when installing chains to the cylinder heads that washers are used under the chains and bolt heads. Tighten the bolts to 20 ft. lbs. (27 Nm).
  52.  


CAUTION
Failure to properly secure the engine lift to the aluminum cylinder heads can result in personal injury.

  1. Position a support under the transaxle rear extension. It may be necessary to raise the support as the engine is being removed.
  2.  
  3. Remove the engine to transaxle bolt, then remove the engine.
  4.  
  5. To install, reverse the removal process noting the following:
    1. Before installing the flex plate-to-converter bolts, make sure that the weld nuts on the converter are flush with the flex plate, and the converter rotates freely by hand.
    2.  
    3. Use only new O-rings at all connections.
    4.  
    5. Adjust the throttle valve cable as outlined in Drive Train .
    6.  

  6.  

 
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