Engine Replacement

Engine Replacement

Special Tools

J-38185 - Hose Clamp Pliers

Removal Procedure

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Service and Repair.
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).




3. Disconnect 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).
4. Disconnect the evaporative emission (EVAP) line (3) quick connect fitting from the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
5. Disconnect the fuel feed pipe clip (2) from the fuel line bracket.




6. Disconnect the transaxle shift cable clip (1) from the fuel line bracket.
7. Remove the battery tray. Refer to Battery Tray Replacement (Service and Repair).




8. Reposition the vacuum brake booster hose clamp (1) at the intake manifold.
9. Disconnect the vacuum brake booster hose (2) from the intake manifold. Reposition the brake booster hose out of the way.




10. Reposition the coolant recovery inlet hose clamp (2) at the cylinder head.
11. Disconnect the coolant recovery inlet pipe clip from the fuel rail.
12. Disconnect the coolant recovery inlet hose (1) from the cylinder head. Reposition the hose/pipe out of the way.




13. Reposition the radiator inlet hose clamp using the J-38185 - pliers.
14. Disconnect the radiator inlet hose from the cylinder head.
15. Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (Radiator Hose).




16. Reposition the heater inlet hose clamp (1) at the thermostat housing.
17. Disconnect the heater inlet hose (2) from the thermostat housing.
18. Reposition the coolant recovery reservoir/heater inlet hose (3) clamp at the thermostat housing.
19. Disconnect the coolant recovery reservoir/heater inlet hose (4) from the thermostat housing.
20. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
21. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement (Service and Repair).




22. Unbolt the A/C compressor and reposition out of the way.




23. Remove the positive battery cable to starter motor nut (4).
24. Disconnect the positive battery cable lead (1) from the starter motor.
25. Reposition the positive battery cable from in between the starter and the engine.




26. If equipped with the LE5 engine, perform the following steps:

1. Disconnect the generator electrical connector (1).
2. Reposition the engine harness boot (3).
3. Remove the generator nut (2).
4. Remove the engine harness lead (4) from the generator.

27. Lower the vehicle.




28. Remove the transaxle shift cable from the range select lever.
29. Release the shift control cable retaining clip and remove the cable from the shift control cable bracket.





Note: The radiator/condenser/fan assembly will stay in the vehicle during engine removal.

30. Using long tie straps, secure the radiator/condenser/fan assembly to the radiator support.
31. Raise the vehicle and remove the front wheels and tires. Refer to Tire and Wheel Removal and Installation (Service and Repair).
32. Remove the front wheelhouse panel. Refer to Front Wheelhouse Panel Splash Shield Replacement (Front Wheelhouse Panel Splash Shield Replacement).

Note: A piece of hardwood should be used between the transaxle and the frame. This wood will support the engine when the left side engine mounts bolts are removed.

33. Install a piece of hardwood 1 x 2 x 4 between the transaxle and the frame.

Note: A piece of hardwood should be used between the oil pan and the frame. This wood will support the engine when the right side engine mounts are removed.

34. Install a piece of hardwood 1 x 2 x 4 between the oil pan and the frame.




35. Drain the transaxle fluid.
36. If equipped with the 4T45, remove the transaxle oil cooler hose to transaxle nut (1).
37. If equipped with the 4T45, disconnect the transaxle oil cooler hoses from the transaxle.
38. If equipped with the 6T40, disconnect the fluid cooler hoses at the transmission. Refer to Fluid Cooler Inlet Hose Replacement (Fluid Cooler Inlet Hose Replacement) and Fluid Cooler Outlet Hose Replacement (Fluid Cooler Outlet Hose Replacement).
39. If equipped with the 6T70, disconnect the fluid cooler pipes from the transmission. Refer to Transmission Fluid Cooler Pipe Replacement - Front (Transmission Fluid Cooler Pipe Replacement - Front) and Transmission Fluid Cooler Pipe Replacement - Rear (Transmission Fluid Cooler Pipe Replacement - Rear).
40. Remove the catalytic converter. Refer to Exhaust Manifold Pipe Replacement (Exhaust Manifold Pipe Replacement).
41. Disconnect the intermediate shaft from the steering gear. Refer to Intermediate Steering Shaft Replacement (Intermediate Steering Shaft Replacement).
42. Disconnect the tie rods from the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement (Steering Linkage Outer Tie Rod Replacement).
43. Disconnect the stabilizer links from the stabilizer shaft. Refer to Stabilizer Shaft Link Replacement (Service and Repair).
44. Disconnect the lower control arms from the steering knuckles. Refer to Lower Control Arm Replacement (Front Suspension).
45. Remove the wheel drive shafts. Refer to Wheel Drive Shaft Replacement (Wheel Drive Shaft Replacement).
46. Lower the vehicle.




47. Remove the engine mount to bracket bolts (1).




48. Remove the transaxle mount to transaxle bolts.
49. Raise the vehicle.





Note: During the powertrain removal support the vehicle body by placing a jack at the rear of the vehicle.

50. Position an engine support table under the powertrain assembly.

Note: Blocks of wood can be used between the front of the frame and the oil pan to table in order to level the powertrain during the removal.

51. With the table positioned, fully raise the table to contact with the powertrain assembly.
52. Remove the frame to body bolts. Discard the bolts.

Note: When lowering the engine/transaxle assembly, verify all brake pipes, shifter cables and other components are not interfering with the removal.

53. Lower the engine table and raise the body on the hoist until the engine/transaxle and frame are separated from the vehicle.




54. Disconnect the engine wiring harness electrical connector (1) from the throttle actuator.
55. Disconnect the engine wiring harness electrical connector (8) from the fuel injector wiring harness electrical connector (7).
56. Disconnect the engine wiring harness clip (3) from the oil level indicator tube bracket.




57. Disconnect the engine wiring harness electrical connectors (1) from the ignition coils.
58. Disconnect the engine wiring harness electrical connectors (2, 3) from the camshaft actuators.




59. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor.
60. Disconnect the engine wiring harness electrical connector (2) from the oil pressure sensor.
61. Disconnect the engine wiring harness electrical connector (3) from the knock sensor.




62. Disconnect the engine wiring harness electrical connector (1) from the intake camshaft position (CMP) sensor.
63. Disconnect the engine wiring harness electrical connector (2) from the EVAP emission canister purge solenoid valve.




64. Disconnect the engine wiring harness electrical connector (1) from the exhaust CMP sensor.




65. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor.
66. Disconnect the engine wiring harness electrical connector (3) from the heated oxygen sensor (HO2S) electrical connector.
67. Remove the engine wiring harness clip (5) from the stud.




68. Remove the engine wiring harness ground bolt (1) and reposition the ground terminal from the engine.
69. Gather all branches of the engine wiring harness and reposition the harness out of the way.




70. Remove the starter motor bolts and the starter.




71. Remove the torque converter to flexplate bolts (1).
72. Install a suitable lifting device to the engine.




73. If equipped with the 4T45, remove the transaxle bolts from the engine.




74. If equipped with the 6T40, remove the transaxle bolts (1, 2, 3, 4) from the engine.
75. If equipped with the 6T70, remove the bolts (1, 2,) from the engine.
76. If equipped with the 6T40, remove the intermediate drive shaft. Refer to Wheel Drive Shaft Replacement (Wheel Drive Shaft Replacement).
77. Separate the engine from the transaxle.
78. Install the engine to a suitable engine stand.

Installation Procedure




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

Caution: Refer to Fastener Caution (Fastener Caution).

3. Install the transaxle bolts to the engine and tighten to 75 Nm (55 lb ft).




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




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




7. Gather all branches of the engine wiring harness and position the harness to the engine.
8. 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).




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




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




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




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




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




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




23. Position the powertrain support table under the vehicle.
24. Raise the powertrain into position under the vehicle.
25. With the table positioned, if required, lower the vehicle over the powertrain.
26. 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.
27. Install the NEW frame to body bolts and tighten to 155 Nm (114 lb ft).
28. Lower the vehicle.




29. 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.

30. Install the engine mount to bracket bolts (1) and tighten to 50 Nm (37 lb ft).
31. Raise and support the vehicle.
32. Install the wheel drive shafts. Refer to Wheel Drive Shaft Replacement (Wheel Drive Shaft Replacement).
33. Connect the control arm to the steering knuckles. Refer to Lower Control Arm Replacement (Front Suspension).
34. Connect the stabilizer links to the stabilizer. Refer to Stabilizer Shaft Link Replacement (Service and Repair).
35. Connect the outer tie rods to the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement (Steering Linkage Outer Tie Rod Replacement).
36. Connect the intermediate shaft to the steering gear. Refer to Intermediate Steering Shaft Replacement (Intermediate Steering Shaft Replacement).
37. Install the catalytic converter. Refer to Exhaust Manifold Pipe Replacement (Exhaust Manifold Pipe Replacement).
38. If equipped with the 4T45, connect the transaxle oil cooler hoses to the transaxle.



39. If equipped with the 4T45, install the transaxle oil cooler hose to transaxle nut (1) and tighten to 4 Nm (27 lb in).
40. If equipped with the 6T40, connect the fluid cooler hoses to the transaxle.
42. Remove the wood from between the oil pan and the frame.
43. Remove the wood from between the transaxle and the frame.
44. Install the front wheelhouse panel. Refer to Front Wheelhouse Panel Splash Shield Replacement (Front Wheelhouse Panel Splash Shield Replacement).
45. Install the front wheels and tires. Refer to Tire and Wheel Removal and Installation (Service and Repair).
46. Lower the vehicle.




47. Position the radiator/condenser/fan assembly. Remove the tie straps.




48. Install the shift control cable to the shift control cable bracket and engage the shift control cable retaining clip.
49. Install the transaxle shift cable to the range select lever.
50. Raise and support the vehicle.




51. If equipped with the LE5 engine, perform the following steps:

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).




52. Position and install the positive battery cable between the starter and the engine.
53. Connect the positive battery cable lead (1) to the starter motor.
54. Install the positive battery cable to starter motor nut (4) and tighten to 9 Nm (80 lb in).




55. Install the A/C compressor with the bolts and tighten to 50 Nm (37 lb ft).
56. Lower the vehicle.




57. Connect the coolant recovery reservoir/heater inlet hose (4) to the thermostat housing.
58. Position the coolant recovery reservoir/heater inlet hose clamp (3) at the thermostat housing.
59. Connect the heater inlet hose (3) to the thermostat housing.
60. Position the heater inlet hose clamp (1) at the thermostat housing.
61. Position the radiator inlet hose clamp using the J-38185 - pliers.
62. Connect the radiator inlet hose to the cylinder head.




63. Install the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (Radiator Hose).




64. Connect the coolant recovery inlet hose (1) to the cylinder head.
65. Connect the coolant recovery inlet pipe clip to the fuel rail.
66. Position the coolant recovery inlet hose clamp (2) at the cylinder head.




67. Connect the vacuum brake booster hose (2) to the intake manifold.
68. Position the vacuum brake booster hose clamp (1) at the intake manifold.
69. Install the battery tray. Refer to Battery Tray Replacement (Service and Repair).




70. Connect the transaxle shift cable clip (1) to the fuel line bracket.




71. Connect the fuel feed pipe clip (2) to the fuel line bracket.
72. 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).
73. 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).
74. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
75. Fill the transaxle with fluid. Refer to the appropriate procedure:

* Transmission Fluid Level and Condition Check (Transmission Fluid Level and Condition Check) for the 4T45 transmission
* Transmission Fluid Level and Condition Check (Transmission Fluid Level and Condition Check) for the 6T40 transmission
* Transmission Fluid Level and Condition Check (Transmission Fluid Level and Condition Check) for the 6T70 transmission

76. Refill the engine with oil. Refer to Engine Oil and Oil Filter Replacement (Service and Repair).
77. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn (Testing and Inspection).
78. Start the engine and allow the engine to run, inspect for leaks. Correct as necessary.