Engine Replacement

Engine Replacement

Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the throttle body air inlet duct.
3. Remove the cruise control cable from the engine and reposition the cable away from the engine.

Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle. In order to avoid cruise control cable damage, position the cable out at the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.

4. Remove and discard the accelerator control cable from the engine and reposition the cable away from the engine.
5. Drain the cooling system.
6. Disconnect the radiator hoses from the engine.
7. Disconnect the heater hoses from the engine.
8. Remove the engine mount struts.

Important: Relieve the fuel pressure.

9. Disconnect the fuel lines at quick connects.
10. Remove the upper engine wiring harness from engine and transmission.
11. Remove the vacuum hoses from the engine.
12. Remove the vacuum brake booster hose.
13. Remove the automatic transaxle range selector cable.
14. Raise and support the vehicle. Refer to Vehicle Lifting.
15. Drain the engine oil.
16. Remove the lower engine wiring harness from engine and transmission.
17. Remove the three-way catalytic converter.
18. Remove rear propshaft. (AWD Only)
19. Remove the front tires and wheels.
20. Remove lower radiator baffle assembly.
21. Remove the engine splash shields.
22. Remove the stabilizer shaft links from the lower control arms.
23. Remove the tie rod ends from the steering knuckles.
24. Remove the lower ball joints from the knuckles.
25. Remove the transaxle cooler lines and bracket from the transaxle.
26. Remove A/C compressor bolts and position compressor aside.
27. Disconnect the drive axles from the transaxle.
28. Secure the drive axles to the steering knuckle/struts.

Caution: Failure to disconnect the intermediate shaft from the rack and pinion steering gear stub shaft can result in damage to the steering gear and/or intermediate shaft. This damage may cause loss of steering control, which could result in an accident and possible personal injury

29. Remove the intermediate shaft pinch bolt from the steering gear.





30. Lower the vehicle until the frame contacts the transaxle table.
31. Remove the frame bolts.
32. Raise the vehicle in order to separate the power/rain/frame assembly from the vehicle.
33. Remove starter.
34. Remove the engine flywheel to torque converter bolts.





35. Install engine hoist to engine.
36. Remove engine mount to frame nuts.
37. Remove the engine-to-transaxle bolts (3, 4, 5, 6) and studs (1, 2).
38. Separate and remove the engine from the transaxle/frame and install to the engine stand.

Installation Procedure
1. Remove engine from engine stand.
2. Install and align the engine to the transaxle/frame.

Notice: Refer to Fastener Notice in Service Precautions.





3. Install the engine-to-transaxle bolts (3, 4, 5, 6) and studs (1, 2).
Tighten the bolts (3, 4, 5, 6) and studs (1, 2) to
4. mount to frame nuts.
Tighten nuts to 43 Nm (32 ft. lbs.).
5. Remove engine hoist from engine.
6. Install the engine flywheel to torque converter bolts.
Tighten bolts to 62 Nm (46 ft. lbs.).
7. Install starter.
8. Position the transaxle cable with the power/rain/frame under the vehicle.





9. Lower the vehicle until the frame contacts the transaxle table.
10. Install the new frame bolts.
11. Raise and support the vehicle. Refer to Vehicle Lifting.
12. Remove the transaxle table.

Caution: When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation, the two mating shafts may disengage. Disengagement of the two mating shafts will cause loss of steering control, which could result in personal injury.

13. Install the intermediate shaft pinch bolt to steering gear.
14. Install the drive axles to the transaxle.
15. Install the transaxle cooler lines and bracket to the transaxle.
16. Install A/C compressor and bolts.
17. Install the lower ball joints to the knuckles.
18. Install the tie rod ends to the steering knuckles.
19. Install the stabilizer shaft links to the lower control arms.
20. Install the engine splash shields.
21. Install lower radiator baffle.
22. Install the front tires and wheels.
23. Install the three-way catalytic converter.
24. Install the lower engine wiring harness to engine and transmission.
25. Install rear propshaft. (AWD Only)
26. Lower the vehicle.
27. Install the automatic transaxle range selector cable.
28. Install the vacuum brake booster hose.
29. Install the vacuum hoses to the engine.
30. Install the upper engine wiring harness to engine and transmission.
31. Install the fuel lines at quick connects.
32. Install the engine mount struts.
33. Connect the heater hoses to the engine.
34. Connect the radiator hoses to the engine.

Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle. In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.

35. Install the NEW accelerator control cable to the engine.
36. Install the cruise control cable to the engine.
37. Install the throttle body air inlet duct.
38. Fill the cooling system with engine coolant.
39. Adjust the transaxle fluid level.
40. Fill the engine with oil.
41. Connect the negative battery cable.
42. Perform the CKP system variation learn procedure.
43. Inspect for proper fluid levels and possible fluid leaks.