Part 2

Engine Replacement

Special Tools
* J 38185 Hose Clamp Pliers
* J 43828 Ball Joint Remover
* J 44015 Steering Linkage Installer

Installation Procedure




1. Install a suitable lifting devise to the engine.
2. Using the lifting devise, position and install the engine to the transaxle.

Caution: Refer to Fastener Caution (Fastener Caution).

3. If equipped with the 4T40, install the transaxle bolts to the engine and tighten to 75 Nm (55 lb ft).
4. If equipped with the 6T40, install the transaxle bolts to the engine and tighten to 75 Nm (55 lb ft).




5. Install the torque converter to flexplate bolts (1) and tighten to 60 Nm (44 lb ft).
6. Remove the engine lifting devise.




7. Install the starter motor and bolts and tighten to 53 Nm (39 lb ft).




8. Gather all branches of the engine wiring harness and position the harness to the engine.
9. Position the engine wiring harness ground terminal to the engine and install the engine wiring harness ground bolt (1) and tighten to 20 Nm (15 lb ft).




10. Connect the engine wiring harness electrical connector (1) to the ECT sensor.
11. Connect the engine wiring harness electrical connector (3) to the HO2S electrical connector.
12. Install the engine wiring harness clip (5) to the stud.




13. Connect the engine wiring harness electrical connector (1) to the exhaust CMP sensor.




14. Connect the engine wiring harness electrical connector (1) to the intake CMP sensor.
15. Connect the engine wiring harness electrical connector (2) to the EVAP emission canister purge solenoid valve.




16. Connect the engine wiring harness electrical connector (1) to the CKP sensor.
17. Connect the engine wiring harness electrical connector (2) to the oil pressure sensor.
18. Connect the engine wiring harness electrical connector (3) to the knock sensor.




19. Connect the engine wiring harness electrical connectors (1) to the ignition coils.
20. Connect the engine wiring harness electrical connectors (2, 3) to the camshaft actuators.




21. Connect the engine wiring harness electrical connector (1) to the throttle actuator.
22. Connect the engine wiring harness electrical connector (8) to the fuel injector wiring harness electrical connector (7).
23. Install the engine wiring harness clip (3) to the oil level indicator tube bracket.




24. Position the powertrain and support table under the vehicle.
25. Raise the powertrain into position under the vehicle.
26. With the table positioned, if required, lower the vehicle over the powertrain.
27. Align the lower radiator pins with the frame. Ensure all hoses and electrical harnesses are correctly routed and free from the loading path of the powertrain.
28. Install the NEW frame to body bolts and tighten to 155 Nm (114 lb ft).
29. Lower the vehicle.




30. Install the transaxle mount to transaxle bolts and tighten to 55 Nm (41 lb ft).





Note: The engine mount to bracket bolts must be hand started. Do not pry the engine mount to align the holes.

31. Install the engine mount to bracket bolts (1) and tighten to 50 Nm (37 lb ft).
32. Raise and support the vehicle.
33. Install the wheel drive shafts. Refer to Wheel Drive Shaft Replacement (Wheel Drive Shaft Replacement).




34. Install the control arm ball studs into the steering knuckles.
35. Install the ball stud nuts and tighten to 40 Nm (30 lb ft).
36. Continue to tighten the nuts only enough to align the castle nut slots with the ball stud, install NEW cotter pins.




37. Connect the stabilizer links to the stabilizer shaft and install the stabilizer link to stabilizer shaft nuts and tighten to 65 Nm (48 lb ft).




38. Connect the outer tie rods to the steering knuckles.
39. Use the J 44015 in order to seat the ball stud taper to 40 Nm (30 lb ft).
40. Remove the J 44015 .




41. Install NEW outer tie rod to steering knuckle nuts and tighten to 25 Nm (48 lb ft) plus 90 degrees.




42. Position the intermediate shaft to the steering gear and install a NEW pinch bolt and tighten to 34 Nm (25 lb ft).
43. Install the catalytic converter. Refer to Exhaust Manifold Pipe Replacement (LE5) (Service and Repair).




44. If equipped with the 4T45, install the transaxle oil cooler lines to the transaxle.
45. If equipped with the 4T45, install the transaxle oil cooler line to transaxle nut (1) and tighten to 4 Nm (27 lb in).
46. If equipped with the 6T40, install the fluid cooler lines at the transaxle. Refer to Fluid Cooler Inlet Hose Replacement (Service and Repair) and Fluid Cooler Outlet Hose Replacement (Service and Repair).




47. Remove the wood from between the oil pan and the frame.
48. Remove the wood from between the transaxle and the frame.
49. Install the front wheelhouse panel. Refer to Front Wheelhouse Panel Splash Shield Replacement (Service and Repair).
50. Install the front wheels and tires. Refer to Tire and Wheel Removal and Installation (Service and Repair).
51. Lower the vehicle.




52. Unsecure and position the radiator/condenser/fan assembly.




53. Install the shift control cable to the shift control cable bracket and engage the shift control cable retaining clip.
54. Install the transaxle shift cable to the range select lever.
55. Raise and support the vehicle.




56. LAT only, install the auxiliary heater water pump and bolt and tighten to 9 Nm (80 lb in).




57. LAT only, connect the engine wiring harness electrical connector (2) to the auxiliary heater water pump.




58. LE5 only:

1. Install the engine harness lead (4) to the generator.
2. Install the generator nut (2) and tighten to 20 Nm (15 lb ft).
3. Seat the engine harness boot (3).
4. Connect the generator electrical connector (1).




59. Position and install the positive battery cable between the starter and the engine.
60. Install the positive battery cable lead (1) to the starter motor.
61. Install the positive battery cable to starter motor nut (4) and tighten to 9 Nm (80 lb in).




62. Position the A/C compressor and install the bolts and tighten to 50 Nm (37 lb ft).




63. LAT only, install the generator control module coolant pump (2) and bolt (3) and tighten to25 Nm (18 lb ft).




64. LAT only, connect the engine wiring harness electrical connector (1) to the generator control module coolant pump.
65. Connect the engine wiring harness electrical connector (2) to the A/C compressor.
66. Lower the vehicle.




67. Install the coolant recovery reservoir/heater inlet hose (4) to the thermostat housing.
68. Position the coolant recovery reservoir/heater inlet hose clamp (3) at the thermostat housing.
69. Install the heater inlet hose (3) to the thermostat housing.
70. Position the heater inlet hose clamp (1) at the thermostat housing.




71. LAT only, connect the engine wiring harness electrical connector (1) to the transaxle auxiliary pump module.




72. LAT only, install the generator control module coolant hose to the generator control module.
73. LAT only, position the generator control module coolant hose clamp (1) at the generator control module.




74. Reposition the radiator inlet hose clamp using the J 38185 .
75. Remove the radiator inlet hose from the cylinder head.
76. Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (LE5) (Service and Repair)Radiator Outlet Hose Replacement (LAT) (Service and Repair)Radiator Outlet Hose Replacement (LY7) (Service and Repair).




77. Position and install the coolant recovery inlet hose (1) to the cylinder head.
78. Install the coolant recovery inlet pipe clip to the fuel rail.
79. Install the coolant recovery inlet hose clamp (2) at the cylinder head.




80. Position and install the vacuum brake booster hose (2) to the intake manifold.
81. Position the vacuum brake booster hose clamp (1) at the intake manifold.
82. Install the generator starter. Refer to Generator with Starter Replacement ().
83. Install the battery tray. Refer to Battery Tray Replacement (LZ4, LY7, and LE5) ()Battery Tray Replacement (LAT) ().




84. Install the transaxle shift cable clip (1) to the fuel line bracket.




85. Install the fuel feed pipe clip (2) to the fuel line bracket.
86. Connect the EVAP line (3) quick connect fitting to the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
87. Connect the fuel feed pipe (1) quick connect fitting at the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
88. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
89. Fill the transaxle with fluid. Refer to Transmission Fluid Check (Transmission Fluid Checking Procedure) or Transmission Fluid Check (Transmission Fluid Check).
90. Refill the engine with oil. Refer to Engine Oil and Oil Filter Replacement (Service and Repair).
91. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn (Service and Repair).
92. Start the engine and allow the engine to run, inspect for leaks. Correct as necessary.