Powertrain Removal and Installation

Powertrain Removal and Installation

Removal Procedure

1. Open the trunk.
2. Disconnect the electronic suspension control module connectors from the module.
3. Close the trunk.
4. Disconnect the battery negative cable.
5. Recover the air conditioning (A/C) refrigerant.
6. Remove the fuel injector sight shield.
7. Relieve the fuel system pressure.




8. Disconnect the evaporative emission (EVAP) canister purge pipe (1) from the chassis purge pipe (2).
9. Cap the open pipes in order to prevent possible contamination.
10. Disconnect the fuel inlet quick-connect fitting at the fuel line and secure.

Important: Cap the hoses and inlets when separating the cooling system components. This prevents dirt and other contaminants from entering the cooling system.

11. Remove the air cleaner assembly.
12. Remove the radiator.
13. Remove the surge tank.
14. Remove the air conditioning condenser.
Caution: Refer to Brake Fluid Irritant Caution.

Important: The brake hydraulic system does not need to be opened.




15. Disconnect the vacuum brake booster hose from the brake booster.




16. Disconnect the electrical connector (1) from the brake fluid level sensor.




17. Remove the brake master cylinder nuts from the brake booster studs.
18. Pull the master cylinder forward out of contact with the brake booster studs.
19. Secure the master cylinder to the engine.




20. Remove the bolts from the intermediate steering shaft.
21. Disconnect the steering shaft from the steering gear.
22. Tie-wrap the steering shaft to the engine.
23. Remove the battery.
24. Remove the battery tray.




25. Remove the ground strap nut and terminal from the stud on the frame.




26. Disconnect the A/C electrical connector from the pressure sensor.
27. Remove the UHJB from the wheelhouse.
28. Disconnect the wiring harness connector from the UHJB.
29. Secure the wiring harness to the engine.
30. Raise and support the vehicle.
31. Remove the front wheels and tires.
32. Remove the right front wheelhouse panel (access to the engine control module (ECM)/transmission control module (TCM) electrical connectors).
33. Disconnect and secure the following wiring harness electrical connectors to the top of engine:
^ The ECM-Refer to Engine Control Module Replacement.
^ The engine electrical harness-Refer to Underhood Electrical Center or Junction Block Replacement.
34. Disconnect A/C lines from front of dash connections.
35. Disconnect heater hoses from heater pipes.
36. Disconnect the front wheel speed sensor electrical connectors.




37. Disconnect the road sensing suspension position sensor links from the front lower control arms.
38. Support the lower control arm with a straight jack.




39. Remove the shock absorber lower mounting bolts.
40. Disconnect the upper ball joint from the suspension knuckle.
41. Remove the straight jack from the control arm.
42. Repeat steps-through-for the other side of the vehicle.
43. Remove the rear tire and wheel assemblies.




44. Disconnect the rear wheel speed sensor electrical connectors.




45. Disconnect the road sensing suspension position sensor links from the rear lower control arms.
46. Support the lower control arm with a straight jack.




47. Remove the rear shock absorber lower mounting bolt.
48. Disconnect the upper ball joint from the suspension knuckle.
49. Remove the straight jack from the control arm.
50. Repeat steps-through-for the other side of the vehicle.
51. Remove the RH muffler assembly.
52. Remove the LH muffler assembly.
53. Remove the exhaust intermediate pipe.




54. Remove the bolts from the driveline tunnel closeout panel.
55. Remove the driveline tunnel closeout panel.




56. Remove the nuts retaining the transmission shift cable bracket to the transmission.




57. Disconnect the transmission shift control cable from the transmission shift lever. Unsnap to release the cable.
58. Reposition the transmission shift cable and bracket.
59. Position the powertrain table under the front cradle.
60. Position the powertrain table under the rear cradle.
61. With the aid of an assistant, slowly lower the vehicle onto the powertrain tables.




62. Using HAND TOOLS ONLY, remove the front and rear crossmember nuts.
63. Carefully raise the vehicle to clear the supported powertrain assembly.

Installation Procedure

1. Position the powertrain under the vehicle.
2. With the aid of an assistant, slowly lower the vehicle onto the powertrain.
3. Guide the front and rear cradle into the cradle bolts.

Notice: Refer to Fastener Notice.

4. Using HAND TOOLS ONLY, install the front and rear cradle nuts.

Tighten the nuts to 110 N.m (81 lb ft).

5. Attach the transmission shift cable bracket to the transmission.




6. Install the nuts retaining the transmission shift cable bracket to the transmission.

Tighten the nuts to 20 N.m (15 lb ft).




7. Connect the transmission shift cable to the transmission shift lever.




8. Install the driveline tunnel closeout panel.
9. Install the bolts to the driveline closeout panel.

Tighten the bolts to 10 N.m (89 lb in).

10. Install the RH muffler assembly.
11. Install the LH muffler assembly.
12. Install the exhaust intermediate pipe.
13. Connect the upper ball joint to the right knuckle.




14. Install the rear shock absorber lower mounting bolts.

Tighten the bolts to 28 N.m (21 lb ft).




15. Connect the road sensing suspension position link to lower control arm.
16. Repeat steps-through-for the other side of the vehicle.




17. Connect the rear wheel speed sensor electrical connectors.
18. Install the rear tire and wheel assemblies.
19. Connect the upper ball joint to the right front suspension knuckle.




20. Install the shock absorber lower mounting bolts.




21. Connect the road sensing suspension position sensor link to the front lower connect arm.




22. Connect the front wheel speed sensor electrical connector.
23. Repeat steps-through-for other side of vehicle.
24. Install the master cylinder to the brake booster.
25. Install the intermediate steering shaft to the steering column.




26. Connect the vacuum brake booster hose to the brake booster.
27. Connect the heater hoses to the heater pipes.
28. Connect the A/C lines to the front of dash connections.




29. Attach the engine ground cable to the right side body frame rail.

Tighten to 8 N.m (71 lb in).

30. Connect the following wiring harness electrical connectors:
^ The ECM-Refer to Engine Control Module Replacement.
^ C101 engine electrical harness-Refer to Underhood Electrical Center or Junction Block Replacement.
31. Install the right front wheelhouse panel.
32. Install the front wheels and tires.
33. Connect the UHJB to the wheelhouse.




34. Connect the A/C electrical connector to the pressure sensor.
35. Install the battery tray.
36. Install the battery.
37. Install the air conditioning condenser.
38. Install the radiator.
39. Install the surge tank.
40. Install the air cleaner assembly.
41. Connect the fuel inlet quick-connect fitting to the fuel rail.




42. Connect the EVAP emission canister purge pipe (1) to the chassis purge pipe (2).
43. Install the fuel injector sight shield.
44. Charge the air conditioning (A/C) refrigerant.
45. Connect the battery negative cable.
46. Program the transmitters.
47. Fill the crankcase with the proper quantity and grade of engine oil.
48. Reset the oil life monitoring system.
49. Perform the engine pre-lubrication procedures.
50. Start the engine.
51. Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.
52. Inspect for fuel, oil, and/or coolant leaks while the engine is running.
53. Perform a final inspection for the proper engine oil and coolant levels.