Removal and Replacement

Removal Procedure

^ Tools Required
- J38185 Hose Clamp Pliers
- J37097-A Hose Clamp Remover/Installer
- J39580 Universal Engine Support Table





1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure.
2. Recover the A/C Refrigerant System. Refer to Refrigerant Recovery and Recharging in Heating and Air Conditioning.
3. Remove the upper filler panel. Refer to Filler Panel Replacement - Upper.
4. Disconnect the connectors from the PCM. Refer to PCM Replacement/Programming.
5. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
6. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
7. Drain the engine oil. Refer to Engine Oil and Oil Fitter Replacement.
8. Remove the two nuts (2) from the intake manifold sight shield (1).
9. Remove the sight shield (1) from the engine.





10. Position the J37097-A to the clamp in order to remove the inlet radiator hose (1) from the engine.
11. Position the J38185 to the clamp in order to remove the outlet radiator hose (2) from the thermostat housing.





12. Remove the upper transaxle oil cooler line retaining bolt from the fan shroud.
13. Slide the plastic cap off the upper transaxle oil cooler line quick connect fitting.
14. Remove the internal spring clip from the transaxle oil cooler fitting.
15. Remove the upper transaxle oil cooler line from the radiator.
16. Disconnect the lower transaxle oil cooler line from the radiator.





17. Remove the surge tank inlet pipe from the engine. Refer to Surge Tank Pipe Replacement - Inlet in Cooling System.

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.

18. Remove the accelerator control cable from the throttle body. Refer to Accelerator Controls Cable Replacement.
19. Disconnect the cruise control cable from the throttle body. Refer to Cruise Control Cable Replacement.





20. Disconnect the heater hoses (1,2) from the engine.
21. Disconnect the two brake pipes from the master cylinder.
Plug the open outlet ports to prevent fluid loss and contamination.





22. Remove the bracket and shift cable (1) from the manual shift lever (2) and position aside.
23. Disconnect the vacuum hose from the brake booster.
24. Disconnect the EVAP hose from the EVAP purge valve.
25. Disconnect the fuel inlet and return quick-connect fittings at the fuel rail. Position aside.





26. Disconnect the engine ground cable (2) from the body frame rail.
27. Disconnect the main engine harness.
28. Disconnect the electrical harness from the underhood fuse block. Refer to Underhood Fuse Block Replacement.





29. Remove the right and left strut tower bolts.
30. Raise and support the vehicle. Refer to Vehicle Lifting.
31. Remove the right and left wheels. Refer to Tire and Wheel Removal and Installation.





32. Disconnect the real time dampening sensor links (1) from the lower control arms.
33. Disconnect the right and left wheel speed sensor connectors.
34. Disconnect the right and left road sensing suspension electrical connectors.
35. Disconnect the two brake pipes from both front frame brackets.
36. Disconnect the two rear brake pipes at the rear of the engine frame.
37. Remove the air deflector. Refer to Air Deflector Replacement - Front.

Important: Engine oil cooler quick connect fittings must be replaced whenever they are removed from the engine oil filter adapter.





38. Remove the engine oil cooler quick connect fittings from the engine oil filter adapter, with the oil lines still attached, and position aside.
39. Remove the dust cover from the quick connect joint.





40. Remove the internal spring clip from the engine oil cooler fittings.





41. Remove the engine oil cooler lines from the cooler fittings.





42. Disconnect the A/C discharge hose from the compressor.





43. Disconnect the A/C suction hose from the compressor.

Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the coil assembly in the steering column to become uncentered which will cause damage to the coil assembly.





44. Lock the steering column by removing the ignition key from the lock cylinder.
45. Remove the intermediate shaft pinch bolt.
46. Disconnect the intermediate shaft from the steering gear.
47. Disconnect the wheel speed and brake wear sensors at the right and left strut towers.
48. Disconnect the post HO2S at the sensor pigtail.
49. Remove the exhaust front pipe. Refer to Front Pipe Replacement.





50. Remove the brace between the engine oil pan and the transaxle case.
51. Remove the torque converter cover. Refer to Torque Converter Cover Replacement in Transmission and Drivetrain.

Important: Mark the flywheel to torque converter relationship prior to removal of the bolts.

52. Remove the torque converter to flywheel bolts.
53. Lower the vehicle.





54. Position the J39580 powertrain support dolly under the engine assembly.





55. If the powertrain support dolly is unavailable. Support the powertrain with four suitable jackstands.





56. Remove the nut securing the right engine mount to the engine mount bracket.





57. Remove the nut (1) securing the left transaxle mount to the transaxle mount bracket.

Caution: To avoid any vehicle damage, serious personal injury or death when more components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed.

58. Secure the front hoist pads to the vehicle.





59. Remove the six frame mount bolts (3).
60. Raise the vehicle slowly.
61. Attach an engine lift to the engine.





62. Remove the heater pipes. Refer to Heater Pipe Replacement - Inlet and Heater Pipe Replacement - Outlet in Heating and Air Conditioning.
63. Remove the nut (3) securing the coil cassette ground wire to the cylinder head.
64. Disconnect the engine wiring harness from the engine. Refer to Engine Controls Component Views.
65. Remove the bolt securing the crossover pipe to the cylinder head.
66. Remove the power steering pump. Refer to Power Steering Pump Replacement in Steering and Suspension.





67. Remove the fasteners (2,3) securing the rear transaxle brace (1) to the cylinder head.
68. Remove the rear transaxle brace (1).






69. Remove the bolts (1) securing the front transaxle brace (2) to the cylinder head.
70. Remove the front transaxle brace (2).





71. Remove the bolts securing the transaxle brace to the engine.





72. Remove the nut securing the front engine mount to the engine frame.





73. Remove the bolts attaching the engine to the transaxle.
74. Raise the engine from the frame and transaxle assembly.

Installation Procedure





1. Position the engine to the frame and transaxle assembly.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the bolts attaching the engine to the transaxle.
Tighten the bolts to 75 Nm (55 ft. lbs.).





3. Install the nut securing the front engine mount to the engine frame.
Tighten the nut to 70 Nm (52 ft. lbs.).





4. Loosely install the four bolts securing the transaxle brace to the engine.
Tighten the bolts to 50 Nm (37 ft. lbs.).





5. Loosely install the bolts (1) securing the front transaxle brace (2) to the cylinder head.
Tighten the bolts to 50 Nm (37 ft. lbs.).





6. Install the fasteners (2,3) securing the rear transaxle brace (1) to the cylinder head.
^ Tighten the nuts (3) to 50 Nm (37 ft. lbs.).
^ Tighten the bolt (2) to 110 Nm (81 ft. lbs.).





7. Install the bolt securing the crossover pipe to the cylinder head.
Tighten the bolt to 25 Nm (18 ft. lbs.).
8. Connect the engine wiring harness to the engine. Refer to Engine Controls Component Views.
9. Install the nut (3) securing the coil cassette ground wire to the cylinder head.
Tighten the nut to 17 Nm (13 ft. lbs.).
10. Install the heater pipes. Refer to Heater Pipe Replacement - Inlet and Heater Pipe Replacement - Outlet in Heating and Air Conditioning.
11. Install the power steering pump. Refer to Power Steering Pump Replacement in Steering and Suspension.





12. Remove the engine lift from the engine.
13. Position the engine/transaxle assembly under the vehicle.
14. Carefully lower the vehicle over the engine/transaxle assembly.
Using dowel pins in the alignment holes (1), align the engine frame (2) with the vehicle.
15. Install the six frame mounting bolts (3) retaining the frame (2) to the vehicle.
Tighten the frame mounting bolts to 191 Nm (141 ft. lbs.).





16. Install the nut (1) securing the left transaxle mount to the transaxle mount bracket.
Tighten the nut to 80 Nm (59 ft. lbs.).





17. Install the nut securing the right engine mount to the engine mount bracket.
Tighten the nut to 80 Nm (59 ft. lbs.).





18. Remove the J39580 powertrain support dolly from under the engine assembly.
19. Raise and support the vehicle. Refer to Vehicle Lifting.

Important: Line up the flywheel and converter, using the alignment marks made during disassemble.





20. Install the torque converter to flywheel bolts.
Tighten the bolts to 60 Nm (44 ft. lbs.).
21. Install the torque converter cover. Refer to Torque Converter Cover Replacement in Transmission and Drivetrain.
22. Install the oil pan to transaxle brace.
Tighten the bolts to 50 Nm (37 ft. lbs.).
23. Install the exhaust front pipe. Refer to Front Pipe Replacement.





24. Connect the post HO2S at the sensor pigtail.
25. Connect the wheel speed and brake wear sensors at the right and left strut towers.
26. Connect the intermediate shaft to the steering gear.
27. Install the pinch bolt.
Tighten the pinch bolt to 45 Nm (33 ft. lbs.).





28. Connect the A/C suction hose to the compressor.
Tighten the suction hose nut to 20 Nm (15 ft. lbs.).





29. Connect the A/C discharge hose to the compressor.
Tighten the discharge hose nut to 20 Nm (15 ft. lbs.).

Important: Engine oil cooler quick connect fittings must be replaced whenever they are removed from the engine oil filter adapter.





30. Install the engine oil cooler quick connect fittings to the engine oil filter adapter.
Tighten the quick connect fittings to 18 Nm (13 ft. lbs.).





31. Push the engine oil cooler lines fully into the oil cooler quick connect fittings, until a "click" is heard.
32. Tug gently on the cooler lines to ensure proper retention.
33. Slide the dust cover over the quick connect joint.
34. Install the air deflector. Refer to Air Deflector Replacement - Front.





35. Connect the real time dampening sensor links (1) to the lower control arms.
36. Connect the right and left road sensing suspension electrical connectors.
37. Connect the right and left wheel speed sensor connectors.
38. Connect the two brake pipes to both front frame brackets.
Tighten the brake pipes to 15 Nm (11 ft. lbs.).
39. Connect the two rear brake pipes at the rear of the engine frame.
Tighten the brake pipes to 15 Nm (11 ft. lbs.).





40. Position the right and left struts to the strut towers.
41. Install the right and left wheels. Refer to Tire and Wheel Removal and Installation.
42. Lower the vehicle.
43. Install the right and left strut tower bolts and washers.
Tighten the strut tower bolts to 40 Nm (30 ft. lbs.).





44. Connect the engine ground cable (2) to the body frame rail.
45. Connect the main engine harness.
46. Connect the electrical harness to the underhood fuse block. Refer to Underhood Fuse Block Replacement.





47. Install the shift cable (1) to the manual shift lever (2) and the bracket.
48. Connect the vacuum hose to the brake booster.
49. Connect the EVAP hose to the EVAP purge valve.
50. Connect the fuel inlet and return quick-connect fittings at the fuel rail.





51. Connect the heater hoses (1,2) to the engine.
52. Connect the two brake pipes to the master cylinder.
Tighten the brake pipes to 15 Nm (11 ft. lbs.).





53. Install the surge tank inlet pipe to the engine. Refer to Surge Tank Pipe Replacement - Inlet in Cooling System.

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.

54. Install a NEW accelerator control cable to the throttle body. Refer to Accelerator Controls Cable Replacement.
55. Connect the cruise control cable to the throttle body. Refer to Cruise Control Cable Replacement.





56. Connect the lower transaxle oil cooler line to the radiator.

Important: Ensure the transaxle oil cooler line is positioned upwards while tightening.

Tighten the transaxle oil cooler line to 35 Nm (26 ft. lbs.).





57. Secure the spring clip to the fitting.
58. Push the upper transaxle oil cooler line into the radiator quick connect fitting, until a "click" is heard.
59. Tug gently on the cooler line to ensure proper retention.
60. Slide the plastic cap (1) over the quick connect joint.





61. Install the upper transaxle oil cooler line retaining bolt to the fan shroud.
Tighten the transaxle oil cooler line retaining bolt to 6 Nm (53 inch lbs.).





62. Position the J38185 to the clamp in order to connect the outlet radiator hose (2) to the thermostat housing.
63. Position the J37097-A to the clamp in order to connect the inlet radiator hose (1) to the engine.





64. Position the intake manifold sight shield (1) to the engine.
65. Install the two intake manifold sight shield nuts (2).
Tighten the nuts to 3 Nm (27 inch lbs.).
66. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
67. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
68. Connect the connectors to the PCM. Refer to PCM Replacement/Programming.
69. Install the upper filler panel. Refer to Filler Panel Replacement - Upper.
70. Recharge the A/C Refrigerant System. Refer to Refrigerant Recovery and Recharging in Heating and Air Conditioning.
71. Connect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure.
Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement.
73. Operate and test the engine. Refer to Engine Set-Up and Testing.
74. Perform the CKP system Variation learn procedure. Refer to CKP System Variation Learn Procedure.
75. Bleed the hydraulic brake system.
76. Measure the wheel alignment. Refer to Measuring Wheel Alignment.