Engine Replacement

Engine Replacement

Special Tools

- J-38185 Hose Clamp Pliers
- For equivalent regional tools, refer to Special Tools, Tools and Equipment

Removal Procedure

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection, Battery Negative Cable Disconnection and Connection
2. Remove the engine cover. Refer to Engine Cover Replacement, Service and Repair






3. Place a clean drain pan under the radiator drain cock.
4. Loosen the radiator drain cock (1).
5. Drain the cooling system. Refer to Cooling System Draining and Filling, Service and Repair
6. Tighten the radiator drain cock (1).
7. Relieve the high side fuel system pressure. Refer to Fuel Pressure Relief, Service and Repair
8. Discharge the air conditioning (A/C) system. Refer to Refrigerant Recovery and Recharging, Refrigerant Recovery and Recharging
9. Remove the front tires. Refer to Tire and Wheel Removal and Installation, Service and Repair
10. Remove the transmission. Refer to the appropriate procedure:
- Transmission Replacement for the 6L45/6L50/6L80/6L90 transmission, Transmission Replacement
- Transmission Replacement for the Aisin AY6 transmission, Transmission Replacement
- Transmission Replacement for the Tremec 6-speed transmission, Transmission Replacement






11. Remove the oil pan drain plug (1) from the oil pan allow the oil to drain completely. Refer to Engine Oil and Oil Filter Replacement, Service and Repair

Caution: Refer to Fastener Caution, Fastener Caution

12. Install the oil pan drain plug (1) and NEW O-ring seal (2) and tighten to 20 Nm (15 lb ft).
13. Remove the air cleaner outlet duct hose. Refer to Air Cleaner Resonator and Outlet Duct Replacement, Air Cleaner Resonator and Outlet Duct Replacement
14. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement, Service and Repair






15. Remove the check valve (1) from the vacuum brake booster.






16. Release the clamp and remove the power brake booster vacuum hose (1) from the vacuum port on the left side of the intake manifold.






17. Disengage tension on the heater inlet rear and outlet hose clamps (1) at the heater core using J-38185 pliers .
18. Remove the heater inlet rear and outlet hose (2) from the heater core.






Note: Cap or tape off the open A/C components immediately to prevent system contamination.

19. Remove A/C evaporator thermal expansion valve tube nut (1).
20. Remove A/C evaporator thermal expansion valve tube (2) from HVAC module reposition.






21. Working under the vehicle, use paint in order to place match marks on the intermediate steering shaft (1) and on the steering gear pinion shaft (3).
22. Remove the steering gear pinion bolt (2).
23. Remove the thread locking patch and clean the threads on the steering gear pinion bolt.
24. Disconnect the intermediate steering shaft from the steering gear pinion shaft.
25. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle, Service and Repair






26. Remove the brake hose bracket bolt (1) from the front suspension strut.
27. Remove the brake hose bracket bolt (2) from the wheelhouse panel.

Note: The brake caliper bolts must be replaced any time they are removed. Do not reuse the brake caliper bolts.

28. Remove and discard the brake caliper bolts (1).

Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

29. Remove the disc brake caliper and bracket assembly and support with heavy mechanics wire or equivalent.






Note: After the nut has been removed, discard and replace with NEW.

30. Remove the front stabilizer shaft nut (1) and discard the old nut.
31. Reposition the stabilizer link (2).






32. Paint a reference mark (2) of the strut (1) to the steering knuckle (3).






33. Remove the front strut nuts (1) and the bolts (2).

Note: Adjust the hydraulic floor jack so that the front strut has a small amount of pressure on it.

34. Using a hydraulic floor jack, support the steering knuckle.
35. Disconnect all necessary engine harness electrical connectors.
36. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement, Front Bumper Fascia Replacement
37. Convertible vehicle, remove the front end lower structure brace.






38. Remove the rear frame bolts (1).
39. Using a suitable engine support table or equivalent, lower the vehicle until the drivetrain and front suspension frame contacts the engine support table.






40. Remove the front (2) and rear (1) frame bolts.
41. Lower the frame with the engine until clear the body and raise the vehicle at full height.
42. Remove the engine mount nuts and remove the engine from the crossmember.
43. Transfer components as required. Refer to the appropriate procedures.

Installation Procedure

1. Install the engine to the crossmember.
2. Tighten both the engine mount nuts to 80 Nm (59 lb ft).

Caution: Refer to Fastener Caution, Fastener Caution






3. Install the front frame (2) mountings bolts and tighten to 160 Nm (118 lb ft).
4. Install the front frame (1) mountings bolts and tighten to 160 Nm (118 lb ft).






5. Install the rear frame (1) mountings bolts and tighten to 240 Nm (177 lb ft).
6. Convertible vehicle, install the front end lower structure brace.
7. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement, Front Bumper Fascia Replacement
8. Connect all necessary engine harness electrical connectors.






9. Align the front strut (1) with the alignment mark (2).






10. Install the front strut bolts (2).
11. Install the nuts (1) and tighten to 80 Nm (59 lb ft) plus an additional 180 degrees.






12. Install the front stabilizer shaft nut (1) and tighten to 49 Nm (36 lb ft).






13. Install the brake hose bracket bolt (1) to the front suspension strut and tighten to 9 Nm (80 lb in).
14. Install the brake hose bracket bolt (2) to the wheelhouse panel and tighten to 9 Nm (80 lb in).






Note: The brake bolts must be replaced any time they are removed.

15. Install 2 new brake caliper bolts (1) and tighten to 40 Nm (33 lb ft) plus 90 degrees.






16. Working under the vehicle, align the match marks and connect the intermediate steering shaft (1) to the steering gear pinion shaft (3).
17. Apply thread locking adhesive to the steering gear pinion bolt (2).
18. Install the steering gear pinion bolt and tighten to 50 Nm (37 lb ft).






19. Install A/C evaporator thermal expansion valve tube (2) to thermal expansion valve tube.
20. Install A/C evaporator thermal expansion valve tube nut (1) and tighten to 19 Nm (14 lb ft).






Note: Lubricate the inside diameters of the hose with clean coolant prior to installation.

21. Install the heater inlet rear and outlet hose (2) to the heater core.
22. Engage tension on the heater inlet rear and outlet hose clamps (1) at the heater core using J-38185 pliers .






23. Install the power brake booster vacuum hose (1) to the vacuum port on the left side of the intake manifold.






Note: If necessary, a small amount of denatured alcohol may be used as a lubricant for assembly. Do not use soap.

24. Install the check valve to the vacuum brake booster.
25. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement, Service and Repair
26. Install the air cleaner outlet duct hose. Refer to Air Cleaner Resonator and Outlet Duct Replacement, Air Cleaner Resonator and Outlet Duct Replacement
27. Install the transmission. Refer to the appropriate procedure:
- Transmission Replacement for the 6L45/6L50/6L80/6L90 transmission, Transmission Replacement
- Transmission Replacement for the Aisin AY6 transmission, Transmission Replacement
- Transmission Replacement for the Tremec 6-speed transmission, Transmission Replacement
28. Charge the A/C system. Refer to Refrigerant Recovery and Recharging, Refrigerant Recovery and Recharging
29. Fill the engine cooling system. Refer to Cooling System Draining and Filling, Service and Repair
30. Fill the engine oil. Refer to Engine Oil and Oil Filter Replacement, Service and Repair
31. Install the engine cover. Refer to Engine Cover Replacement, Service and Repair
32. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection, Battery Negative Cable Disconnection and Connection