Engine Replacement

Engine Replacement

Removal Procedure

Caution: Refer to Battery Disconnect Caution in Service Precautions.

Notice: Refer to Engine Emission Notice in Service Precautions.

1. Disconnect the negative battery cable.
2. Remove the hood.
3. Remove the fuel injector sight shield.
4. Raise and support the vehicle. Refer to Vehicle Lifting.
5. Drain the engine oil.
6. Drain the cooling system.
7. Remove the torque converter cover.
8. Remove the starter motor.
9. Remove the engine flywheel-to-torque converter bolts.
10. Scribe the torque converter to the flywheel for installation.
11. Remove the transaxle brace.





12. Remove the engine mount lower nuts.
13. Remove the three-way catalytic converter pipe from the right exhaust manifold.
14. Remove the oil level sensor harness retainer bolt.
15. Remove the oil level harness retainer from the engine.
16. Disconnect and reposition the electrical connectors from the following components:
- Vehicle Speed Sensor (VSS)
- Oil pressure sensor
- Oil level sensor
- Knock sensors
- Heated Oxygen (H02) sensor
17. Remove the oil filter adapter housing.
18. Remove the engine ground nut and engine ground from the transaxle stud.





19. Remove the bolt (6) and the stud (1 ) which secure the lower transaxle to the engine.
20. Lower the vehicle while supporting the transaxle.
21. Remove the air cleaner assembly.

Important: Relieve the fuel pressure.





22. Disconnect the fuel lines (1,2) from the fuel rail. Lay the fuel lines aside.
23. Disconnect the fuel vapor line.
24. Remove the throttle and cruise control cables and bracket from the throttle body.





25. Loosen the water pump pulley bolts.
26. Remove the drive belt.
27. Remove the water pump pulley bolts and the water pump pulley.
28. Remove the right and left engine mount struts.
29. Remove the engine mount brackets from the radiator support.
30. Disconnect the positive battery cable.
31. Remove the engine cooling fans.
32. Remove the vacuum booster hose from the engine.
33. Disconnect the A/C vacuum hose from the engine.





34. Remove the power steering pump bolts and pump from the engine. Lay the power steering pump aside.
35. Disconnect the upper engine electrical connectors from the following components:
- Fuel injectors
- Throttle Position (T/P) sensor
- Idle Air Control (IAC) valve
- EVAP purge solenoid
- Exhaust Gas Recirculation (EGR) valve
- Manifold absolute pressure (MAF) sensor
36. Remove upper engine wiring harness from retaining clips and reposition the engine wiring harness for engine removal.
37. Remove the radiator inlet hose from the engine.
38. Remove the radiator outlet hose from the engine.
39. Remove the heater hoses from the drive belt tensioner.





40. Remove the A/C compressor from the engine. DO NOT discharge the A/C system. Secure the compressor to the frame.
41. Install the engine lifting device.





42. Remove the bolts (2,3,4,5) which secure the upper transaxle to the engine.
43. With assistance remove the engine from the vehicle.
44. Remove the flywheel.
45. Install the engine to the engine stand.





46. Remove the oil indicator tube nut from the exhaust manifold.
47. Remove the oil level indicator tube.





48. Remove the left side engine mount bracket bolts.





49. Remove the right side engine mount bracket bolts and the engine mount bracket.
50. Remove the drive belt tensioner.
51. Remove the ignition control module and the ignition control module bracket.
52. Remove the engine mount strut brackets from the left side and the right side.





53. Remove the A/C compressor bracket bolts and bracket.





54. Remove the bracket nuts from the fuel injector sight shield.
55. Remove the bracket from the fuel injector sight shield.
56. Remove the EGR valve adapter from the right cylinder head.
57. Remove the upper intake manifold or the supercharger.





58. Remove the generator brace bracket bolts.
59. Remove the generator brace bracket from the right cylinder head.
60. Remove the left and the right engine lift brackets.
61. Remove the crankshaft balancer.
62. Remove the right exhaust manifold, the left exhaust manifold and the exhaust crossover.

Installation Procedure

Notice: Refer to Engine Emission Notice in Service Precautions.





1. Install the right exhaust manifold, the left exhaust manifold, and the exhaust crossover.
2. Install the crankshaft balancer.
3. Install the engine lift brackets.

Notice: Refer to Fastener Notice in Service Precautions.

4. Install the bolts and nuts to the left and the right engine lift bracket.
Tighten the bolts and nuts to 30 Nm (22 ft. lbs.).
5. Install the generator brace bracket to the right cylinder head.
6. Install the generator brace bracket bolts.
Tighten the bracket bolts to 50 Nm (37 ft. lbs.).
7. Install the upper intake manifold or the supercharger.
8. Install the EGR valve adapter to the right cylinder head.





9. Install the bracket to the fuel injector sight shield.
10. Install the bracket nuts to the fuel injector sight shield.
Tighten the nuts to 30 Nm (22 ft. lbs.).





11. Install the A/C compressor bracket and bolts.
Tighten the bracket bolts to 50 Nm (37 ft. lbs.).
12. Install the engine mount brackets to the left and to the right side.
13. Install the ignition control module bracket and the ignition control module.
14. Install the drive belt tensioner.





15. Install the engine mount bracket.
Install the bracket bolts to the right side engine mount.





16. Install the bracket bolts to the left side engine mount.
Tighten the bracket bolts to 102 Nm (75 ft. lbs.).





17. Install the oil indicator tube to the engine. Ensure that the O-ring is in place. Ensure that the oil level indicator tube is fully seated in the engine.
Tighten the nut on the oil level indicator tube to 19 Nm (14 ft. lbs.).
18. Remove the engine from the engine stand.
19. Install the flywheel.
20. With the aid of an assistant, install the engine to the vehicle.





21. Install the bolts (2,3,4,5) that secure the upper transaxle to the engine.
Tighten the bolts to 75 Nm (55 ft. lbs.).
22. Remove the engine lifting device.





23. Install the A/C compressor and the A/C compressor nuts to the A/C compressor bracket.
Tighten the nuts to 30 Nm (22 ft. lbs.).
24. Install the heater hoses to the drive belt tensioner.
25. Install the radiator outlet hose to the engine.
26. Install the radiator inlet hose to the engine.
27. Reposition the engine wiring to the engine.
28. Connect the upper engine electrical connectors to the following components:
- Manifold Absolute Pressure (MAP) sensor
- Exhaust Gas Recirculation (EGR) valve
- EVAP purge solenoid
- Idle Air Control (IAC) valve
- Throttle Position (T/P) sensor
- Fuel injectors
29. Install the upper engine wiring harness to the retaining clips.





30. Install the power steering pump to the engine.
Tighten the power steering bolts to 34 Nm (25 ft. lbs.).
31. Connect the A/C vacuum hose to the engine.
32. Install the vacuum booster hose to the engine.
33. Install the engine cooling fans.
34. Connect the positive battery cable.
Tighten the cable terminal nut to 15 Nm (11 ft. lbs.).
35. Install the engine mount brackets to the radiator support.
36. Install the engine mount struts to the engine mount strut brackets.





37. Install the water pump pulley.
38. Install the water pump pulley bolts.
Tighten the pulley bolts to 13 Nm (116 inch lbs.).
39. Install the drive belt.
40. Install the throttle cable, the cruise control cable, and the bracket to the throttle body.
41. Connect the fuel vapor line.





42. Connect the fuel lines (1,2) to the fuel rail.
43. Install the throttle body air inlet duct and the air cleaner assembly.
44. Raise the vehicle and remove the transaxle support.





45. Install the bolt (6) and the stud (1) which secure the lower transaxle to the engine.
Tighten the bolt and the stud to 75 Nm (55 ft. lbs.).
46. Install the engine ground to the transaxle stud.
Tighten the engine ground nut to 35 Nm (26 ft. lbs.).
47. Install the oil filter adapter housing.
48. Reposition and connect the electrical connectors to the following components:
- Heated Oxygen (H02) sensor
- Knock sensors
- Oil level sensor
- Oil pressure sensor
- Vehicle Speed Sensor (VSS)
49. Install the oil level sensor harness retainer to the engine.
Tighten the retainer bolt to 10 Nm (89 inch lbs.).
50. Install the three-way catalytic converter pipe to the right exhaust manifold.





51. Install the engine mount lower nuts.
Tighten the nuts to 78 Nm (58 ft. lbs.).
52. Install the transaxle brace.
53. Install the engine flywheel-to-torque converter bolts.
54. Install the starter motor.
55. Install the torque converter cover.
56. Lower the vehicle.
57. Install the fuel injector sight shield.
58. Install the hood.
59. Connect the negative battery cable.
60. Fill the crankcase with engine oil.
61. Fill the cooling system.
62. Inspect for leaks.
63. Perform the CKP system variation learn procedure.