QuestionI've got a '96 Merc Sable SW with a blown engine (3.0 - victor? - the cheaper one) and good tranny. I bought a used engine. I have a garage lift, cherry picker and lots of tools. What is the simplest way to do this change-over? Should I do anything to the new engine before I put it in? (A friend suggested replacing the freeze plugs.) Thanks!
AnswerHello and thanks for the question...I'll try to help.
Removal:
Disconnect battery ground cable.
Disconnect steering coupling at pinch bolt joint inside passenger compartment.
Disconnect engine control sensor wiring from intake air temperature sensor.
Disconnect crankcase ventilation tube and aspirator hose from air cleaner outlet tube.
Remove air cleaner outlet tube.
Drain engine coolant and discharge A/C system.
Relieve fuel system pressure.
Disconnect fuel tubes from fuel injection supply manifold.
Disconnect chassis vacuum supply hose and evaporative emission hose from upper intake manifold, then position hoses out of the way.
Remove electrical ground straps from dash panel.
Disconnect engine control sensor wiring from Powertrain Control Module (PCM) and position wiring out of the way.
Remove connectors for engine control sensor wiring from retaining bracket on power brake booster, then disconnect sensor wiring at two connectors.
Disconnect engine control sensor wiring from mass airflow sensor and evaporative emission canister purge valve.
Remove shield and disconnect accelerator cable and speed control actuator cable from throttle body, then position cable aside.
Remove accelerator bracket from throttle body.
Remove transmission range sensor and manual control lever to transaxle manual lever shaft retaining nut.
Remove connectors for engine control sensor from retaining bracket on top of transaxle, then disconnect wiring at two connectors.
Disconnect wiring connectors from secondary air injection pump relay located on retaining bracket on top of transaxle.
Disconnect fluid cooler inlet tube from transaxle.
Disconnect heater hoses from water pump and water hose connection.
Disconnect upper radiator hose and de-gas tube from water hose connection.
Remove power steering return hose from power steering oil reservoir and drain.
Disconnect alternator wiring harness from alternator, then remove wiring harness retaining clip from alternator mounting bracket.
Disconnect A/C compressor lines from A/C compressor.
Slightly raise and support vehicle, then remove tire and wheel assemblies.
Remove righthand and lefthand stabilizer bar links from stabilizer bar.
Separate righthand and lefthand front suspension lower control arm ball joints from wheel knuckles.
Separate lefthand and righthand tie rod ends from front wheel knuckle.
Remove lefthand and righthand halfshafts from front wheel knuckles.
Raise and support vehicle.
Remove splash shield from radiator support, then drain engine oil.
Remove dual converter Y-pipe.
Disconnect power steering pressure hose from power steering/transaxle fluid cooler connection, then position hose out of the way.
Disconnect lower radiator hose from radiator and radiator overflow hose.
Disconnect starter motor electrical connectors, then remove starter motor.
Disconnect lower fluid cooler tube from transaxle.
Support front subframe, engine and transaxle assembly using Rotunda powertrain lift tool 014-00765 and universal powertrain removal bracket tool 014-00766, or equivalents.
Remove four front subframe retaining bolts, then lower engine, transaxle and front subframe from vehicle.
Disconnect power steering hose from power steering pump.
Install engine lifting eyes D81L-6001-D, or equivalent.
Connect Rotunda engine lifting spreader bar tool D93P-6001-A3, or equivalent, to lifting eyes to support engine and transaxle.
Remove engine and transaxle mounts.
Lift engine and transaxle from front subframe.
Lower engine and transaxle and support transaxle on a level surface.
Remove transaxle to cylinder block bolts, then separate engine from transaxle.
Reverse procedure to install.
It wouldn't hurt to replace the freeze plugs while you have it out. Also a complete re-gasketing of the engine, so you don't have oil leaks after installation.
Erik
