Engine Replacement

Engine Replacement
Removal Procedure
1. Disconnect the negative battery cable.





2. Loosen the 2 intake air duct clamps (1) from air cleaner housing (2) and the throttle body.
3. Remove the air cleaner intake duct from the air cleaner housing and throttle body.
4. Drain the cooling system. Refer to Draining and Filling Cooling System (Static Fill) Draining and Filling Cooling System (Vac-N-Fill).
5. Remove the radiator inlet hose from the engine.
6. Remove the radiator outlet hose from the engine.
7. Remove the heater outlet and inlet hoses from the engine.
8. Remove the vacuum hoses from the upper intake manifold.
9. Remove the brake booster vacuum hose from the upper intake manifold.
10. Remove the fuel lines from the fuel rail.
11. Disconnect the following electrical connectors:
^ The knock sensor (KS)
^ The camshaft position (CMP) sensor
^ The crankshaft position (CKP) sensor
^ The heated oxygen sensor (HO2S)
^ The manifold absolute pressure (MAP) sensor
^ The exhaust gas recirculation (EGR) valve
^ The evaporative emission (EVAP) canister purge solenoid
^ The electronic throttle control
^ The ignition coil
^ The body wiring harness-to-engine harness
^ The engine wiring harness from transmission
12. Remove the engine wiring harness grounds from the transaxle.
13. Remove the engine mount strut.
14. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
15. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement.
16. Remove rear propeller shaft.
17. Remove the catalytic converter.
18. Remove the front tires and wheels.
19. Remove the lower radiator air baffle assembly.
20. Remove the engine splash shields.
21. Remove the stabilizer shaft links from the lower control arms.
22. Remove the tie rod ends from the steering knuckles.
23. Remove the lower ball joints from the knuckles.
24. Remove the A/C compressor bolts and position compressor aside. DO NOT discharge the A/C system. Support the compressor.
25. Disconnect the drive axles from the transaxle.
26. Secure the drive axles to the steering knuckle/struts.

27. 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.

Remove the intermediate shaft pinch bolt from the steering gear.





28. Lower the vehicle until the frame contacts the transaxle table.
29. Remove the frame bolts.
30. Raise the vehicle in order to separate the powertrain/frame assembly from the vehicle.
31. Remove the starter motor.
32. Remove the torque converter covers.
33. Remove the torque converter bolts.





34. Remove the engine mount lower nuts.
35. Remove the transaxle brace.
36. Remove the exhaust crossover pipe.
37. Install engine hoist to engine.





38. Remove the transaxle-to-engine bolts (3, 4, 5, 6) and the studs (1, 2).
39. Support the transaxle.
40. Separate and remove the engine from the transaxle/frame.
41. Install the engine to the engine stand.
42. Remove the flywheel.
43. Remove the drive belt.

Installation Procedure
1. Install the drive belt.
2. Install the flywheel.
3. Remove the engine from the engine stand.
4. Install and align the engine to the transaxle/frame.





5. Notice: Refer to Fastener Notice in Service Precautions.

Install the transaxle-to-engine bolts (3, 4, 5, 6) and the studs (1, 2).
^ Tighten the bolts (3, 4, 5, 6) and the studs (1, 2) to 75 Nm (55 ft. lbs.).
6. Remove the engine hoist from the engine.
7. Install the exhaust crossover pipe.
8. Install the transaxle brace.





9. Install the engine mount lower nuts.
^ Tighten the nuts to 43 Nm (32 ft. lbs.).
10. Install the torque converter bolts.
11. Install the torque converter covers.
12. Install the starter motor.
13. Position the transaxle table with the powertrain/frame under the vehicle.





14. Lower the vehicle until the frame contacts the transaxle table.
15. Install the new frame bolts.
16. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
17. Remove the transaxle table.

18. 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

Install the intermediate shaft pinch bolt to the steering gear.
19. Connect the drive axles to the transaxle.
20. Position compressor to the engine and Install the A/C compressor bolts. Refer to Compressor Replacement.
21. Install the lower ball joints to the knuckles.
22. Install the tie rod ends to the steering knuckles.
23. Install the stabilizer shaft links to the lower control arms.
24. Install the engine splash shields.
25. Install the lower radiator air baffle assembly.
26. Install the front tires and wheels.
27. Install the catalytic converter.
28. Install rear propeller shaft.
29. Lower the vehicle.
30. Fill the crankcase with engine oil. Refer to Engine Oil and Oil Filter Replacement.
31. Install the engine mount strut.
32. Connect the following electrical connectors:
^ The KS
^ The CMP sensor
^ The CKP sensor
^ The HO2S
^ The MAP sensor
^ The EGR valve
^ The EVAP canister purge solenoid
^ The electronic throttle control
^ The ignition coil
^ The body wiring harness-to-engine harness
^ The engine wiring harness from transmission
33. Install the engine wiring harness ground nut to the transaxle stud.
^ Tighten the nut to 35 Nm (26 ft. lbs.).
34. Install the fuel lines to the fuel rail.
35. Install the brake booster vacuum hose to the upper intake manifold.
36. Install the vacuum hoses to the upper intake manifold.
37. Install the heater outlet and inlet hoses to the engine.
38. Install the radiator outlet hose to the engine.
39. Install the radiator inlet hose to the engine.





40. Install the air cleaner intake duct to the air cleaner housing (2) and the throttle body.
41. Tighten the 2 intake air duct clamps (1).
^ Tighten the clamps to 2 Nm (18 inch lbs.).
42. Connect the negative battery cable.
43. Fill cooling system. Refer to Draining and Filling Cooling System (Static Fill) Draining and Filling Cooling System (Vac-N-Fill).
44. Perform a CKP system variation learn procedure. Refer to CKP System Variation Learn Procedure. Service and Repair
45. Inspect for leaks.