Engine Replacement

Engine Replacement

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 intake manifold cover (2). Refer to Intake Manifold Cover Replacement Intake Manifold Cover Replacement.

3. Drain the cooling system. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.

4. Relieve fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) Fuel Pressure Relief (Without CH 48027)Fuel Pressure Relief (CH 48027) Fuel Pressure Relief (CH-48027).





5. Remove the air cleaner outlet duct (2). Refer to Air Cleaner Outlet Duct Replacement Service and Repair.

6. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement Air Cleaner Assembly Replacement.

7. Remove the drive belt. Refer to Drive Belt Replacement Service and Repair.





8. Disconnect the transmission shiftier cable (2) from the transmission. Refer to Range Selector Lever Cable Replacement (Column Shift) Range Selector Lever Cable Replacement (Column Shift)Range Selector Lever Cable Replacement (Floor Shift) Range Selector Lever Cable Replacement (Floor Shift).





9. Remove and reposition the power steering fluid reservoir (1). Refer to Power Steering Fluid Reservoir Replacement Power Steering Fluid Reservoir Replacement

10. Disconnect the surge tank inlet hose (2) from the engine and position aside.

11. Disconnect the brake booster vacuum hose (3) and position aside.

12. Disconnect the fuel pump fuel feed hose from the fuel feed pipe (4). Refer to Metal Collar Quick Connect Fitting Service Service and Repair.

13. Disconnect the surge tank outlet hose (5) from the engine and position aside.

14. Disconnect the ground wire terminals (6) from the transmission.

15. Disconnect the ECM connectors (7) and place the harness on the engine.

16. Remove the engine strut bolt (8).

17. Disconnect the positive battery cable (9) in position cable on the engine.





18. Remove the accessory wiring junction block circuit board (2). Refer to Accessory Wiring Junction Block Replacement Accessory Wiring Junction Block Replacement.

19. Remove the engine harness connector and position on the engine.





20. Disconnect the radiator outlet hose (2) from the engine. Refer to Radiator Outlet Hose Replacement Radiator Outlet Hose Replacement.





21. Disconnect the radiator inlet hose (2) from the engine. Refer to Radiator Inlet Hose Replacement Radiator Inlet Hose Replacement.

22. Disconnect the heater inlet and outlet hoses from the heater core. Refer to Heater Outlet Hose Replacement Heater Outlet Hose Replacement and Heater Inlet Hose Replacement Heater Inlet Hose Replacement.

23. Place the vehicle on the hoist.

24. Remove the radiator air lower baffle and deflector. Refer to Radiator Air Lower Baffle and Deflector Replacement Radiator Air Lower Baffle and Deflector Replacement.

25. Remove both front wheels. Refer to Tire and Wheel Removal and Installation Service and Repair.





26. Remove the left and right wheel drive shafts (2). Refer to Wheel Drive Shaft Replacement Wheel Drive Shaft Replacement.





27. Remove the steering gear bolts (1 and 3) and secure steering gear to the vehicle body. Refer to Steering Gear Replacement Steering Gear Replacement.





28. Remove the front exhaust pipe (2). Refer to Exhaust Front Pipe Replacement Service and Repair.





29. Remove the lower engine mount fasteners (1-3).

30. Disconnect the transmission fluid cooler pipes. Refer to Fluid Cooler Inlet Hose Replacement Fluid Cooler Inlet Hose Replacement and Fluid Cooler Outlet Hose Replacement Fluid Cooler Outlet Hose Replacement.





31. Remove the air conditioning compressor fasteners (1-3) and using mechanics wire, secure the compressor to the radiator support.





32. Position a suitable engine support table under the vehicle and carefully lower the vehicle until the engine cradle is supported by the table.





33. Remove the front and rear frame to the body bolts (1). Refer to Frame Replacement Service and Repair

34. Carefully raise the vehicle from the powertrain.

35. Disconnect and reposition harnesses as required.

36. Lift the powertrain assembly off the frame and place on the floor.

37. Separate the engine from the transmission. Refer to Transmission Replacement Transmission Replacement.

38. Disconnect electrical connectors as necessary.

Installation Procedure

1. Install the engine to the transmission. Refer to Transmission Replacement Transmission Replacement.

2. Place the powertrain assembly on the frame.

3. Place the powertrain and frame assembly on a suitable engine support table.

4. Position the powertrain assembly under the vehicle





5. Install the front and rear frame to the body bolts (1). Refer to Frame Replacement Service and Repair

6. Remove the engine support table.





7. Cut the wire and position the air conditioning compressor.

8. Install the air conditioning fasteners (1-3) and tighten as shown in Air Conditioning Compressor Replacement Air Conditioning Compressor Replacement.

9. Connect the transmission fluid cooler pipes. Refer to Fluid Cooler Inlet Hose Replacement Fluid Cooler Inlet Hose Replacement and Fluid Cooler Outlet Hose Replacement Fluid Cooler Outlet Hose Replacement.





10. Install the lower engine mount fasteners (1-3). Refer to Engine Front Mount Replacement Engine Front Mount Replacement , Engine Rear Mount Replacement Engine Rear Mount Replacement and Transmission Mount Replacement - Left Side Service and Repair.





11. Install the front exhaust pipe (2). Refer to Exhaust Front Pipe Replacement Service and Repair.





12. Place the steering gear in position and install the steering gear bolts (1 and 3). Refer to Steering Gear Replacement Steering Gear Replacement.





13. Install the left and right wheel drive shafts (2). Refer to Wheel Drive Shaft Replacement Wheel Drive Shaft Replacement.

14. Install the front wheels. Refer to Tire and Wheel Removal and Installation Service and Repair.

15. Install the radiator air lower baffle and deflector. Refer to Radiator Air Lower Baffle and Deflector Replacement Radiator Air Lower Baffle and Deflector Replacement.

16. Lower the vehicle.

17. Connect the heater inlet and outlet hoses to the heater core. Refer to Heater Outlet Hose Replacement Heater Outlet Hose Replacement and Heater Inlet Hose Replacement Heater Inlet Hose Replacement.





18. Connect the radiator outlet hose (2) from the engine. Refer to Radiator Outlet Hose Replacement Radiator Outlet Hose Replacement.





19. Connect the radiator outlet hose (2) from the engine. Refer to Radiator Outlet Hose Replacement Radiator Outlet Hose Replacement.





20. Position the engine harness connector in the accessory wiring junction block.

21. Install the accessory wiring junction block circuit board (2). Refer to Accessory Wiring Junction Block Replacement Accessory Wiring Junction Block Replacement.





22. Install the power steering fluid reservoir (1). Refer to Power Steering Fluid Reservoir Replacement Power Steering Fluid Reservoir Replacement

23. Connect the surge tank inlet hose (2) to the engine.

24. Connect the brake booster vacuum hose (3).

25. Connect the fuel pump fuel feed hose to the fuel feed pipe (4). Refer to Metal Collar Quick Connect Fitting Service Service and Repair.

26. Connect the surge tank outlet hose (5) to the engine.

27. Connect the ground wire terminals (6) to the transmission.

28. Connect the ECM connectors (7) to the ECM.

29. Install the engine strut bolt (8).

30. Connect the positive battery cable (9) in position cable on the engine.





31. Connect the transmission shiftier cable (2) to the transmission. Refer to Range Selector Lever Cable Replacement (Column Shift) Range Selector Lever Cable Replacement (Column Shift)Range Selector Lever Cable Replacement (Floor Shift) Range Selector Lever Cable Replacement (Floor Shift).

32. Install the drive belt. Refer to Drive Belt Replacement Service and Repair.

33. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement Air Cleaner Assembly Replacement.





34. Install the air cleaner outlet duct (2). Refer to Air Cleaner Outlet Duct Replacement Service and Repair.

35. Fill the cooling system. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.

36. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.

37. Fill the vehicle with coolant. Refer to Cooling System Draining and Filling Cooling System Draining and Filling.

38. Fill the engine oil. Refer to Engine Oil and Oil Filter Replacement Service and Repair.





39. Install the intake manifold cover (2). Refer to Intake Manifold Cover Replacement Intake Manifold Cover Replacement.

40. Run the engine and check for leaks.