Removal and Replacement

Engine Replacement

Removal Procedure

1. Disconnect the negative battery cable from the battery. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.

2. Drain the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (GE-47716 Fill) Cooling System Draining and Filling (GE-47716 Fill).

3. Recover the air conditioning refrigerant. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging.





4. Disconnect the electrical connector (1).

5. Loosen the clamp (2) and remove air cleaner from air cleaner assembly (3).





6. Loosen the clamp (1) and remove the outlet duct (2).

7. Remove the charge air cooler inlet air hose. Refer to Charge Air Cooler Inlet Air Hose Replacement .

8. Remove the charge air cooler outlet air hose. Refer to Charge Air Cooler Outlet Air Hose Replacement (Automatic Transmission) Charge Air Cooler Outlet Air Hose Replacement (Manual Transmission) .





9. Remove refrigerant hose nut (1) from refrigerant hose (2).





10. Disconnect the fuel feed line (1) and reposition away from the engine. Refer to Fuel Pressure Relief Service and Repair.





11. Disconnect the EVAP hose (1). Refer to Plastic Collar Quick Connect Fitting Service Service and Repair.





12. Disconnect the power brake booster vacuum pipe (1).





13. Reposition the hose clamp (1) and remove the radiator surge tank outlet hose.





14. Disconnect inlet (2) and outlet (1) heater core hoses.





15. On vehicles equipped with a automatic transmission, disconnect the transmission range selector lever cable terminal (1) from the transmission manual shift lever pin.

16. On vehicles equipped with a automatic transmission, press the locking tabs inward in order to release the transmission range selector lever cable (2) from the cable bracket.





17. On vehicles equipped with a manual transmission, using a suitable pry tool, disconnect the shift lever cables (2) from the shift levers (3)

18. On vehicles equipped with a manual transmission, remove the shift lever cables (2) from the cable bracket (1).





19. Remove the ground strap bolt (1) from the battery cable and reposition the strap (2) a side.

20. Remove the battery tray. Refer to Battery Tray Replacement Service and Repair.





21. Remove the ground nuts (1) and put the wiring harness (2) aside.

22. Disconnect the electrical connectors from the engine control module (ECM). Refer to Engine Control Module Replacement Service and Repair.

23. Disconnect the wiring harness from the accessory wiring junction block.





24. Disconnect the wiring harness from the junction connector (1).

25. Place the ECM, transmission and the accessory wiring junction block wiring harnesses on the top of engine assembly.

26. Install the engine support fixture.





27. Remove and DISCARD the lower steering intermediate shaft bolt (1).





Note:
Do Not disconnect the brake hoses from the calipers.

28. Remove the front brake calipers (1) and caliper bolts (2) from the caliper brackets, and then suspend the calipers with mechanics wire to the body.

29. Remove the exhaust system. Refer to Exhaust System Replacement Service and Repair.





30. Remove and DISCARD the stabilizer link nut (1) from the strut assemblies. Refer to Stabilizer Shaft Link Replacement Front Suspension.

31. Disconnect the right wheel drive shaft from the intermediate shaft.

32. Disconnect the front steering knuckles from the strut assemblies. Refer to Steering Knuckle Replacement Service and Repair.

33. Disconnect the electronic power steering connectors from the electronic power steering assembly. Refer to FEP Connectors (Steering Gear) FEP Connectors (Steering Gear).





34. Remove the rear transmission mount bracket to rear mount through bolt (1).





35. Remove the transmission front mount through bolt (1).

36. Using suitable straps or chains, secure the front of vehicle to the hoist arms.

Note:
Use the engine support fixture to slightly raise the powertrain assembly to aid in the removal of the engine and transmission mount bolts.

37. Use the engine support fixture to slightly raise the powertrain assembly to aid in the removal of the engine and transmission mount bolts.





38. Remove and DISCARD the left transmission mount to bracket bolts (1).





39. Remove the engine mount to engine mount bracket bolts (1) and the washers (2).

40. Using a suitable engine support table, lower the vehicle until the drivetrain and front suspension frame contacts the engine support table.

41. Position blocks of wood below the oil pan and transmission to stabilize the powertrain on the support table.

42. Using the engine support fixture, lower the powertrain down until it is resting on the engine support table.





43. Remove the power steering gear inlet and outlet hose bolts (1). Remove the inlet and outlet hose (2) from the steering gear (3).

44. Remove the engine support fixture.

45. Remove the drivetrain and front suspension frame reinforcements from the rear of the frame.

46. Remove the front drivetrain and front suspension frame retaining bolts.

47. Slowly and carefully raise the vehicle, ensure the engine, transmission, radiator assembly and drivetrain suspension frame are free from wiring, hoses and other engine compartment components.

48. Separate the transmission from the engine assembly.

49. Disconnect engine coolant hoses as necessary.

50. Disconnect electrical connectors as necessary.

51. Transfer components as necessary.

Installation Procedure

1. Position the engine to the transmission assembly.

2. Position the engine, transmission, radiator assembly and drivetrain suspension frame under the vehicle.

3. Slowly and carefully lower the vehicle, ensure the engine, transmission, radiator assembly and drivetrain suspension frame are free from wiring, hoses and other engine compartment components.

Caution:
Refer to Fastener Caution Fastener Caution.

4. Install the four front drivetrain and front suspension frame retaining bolts, then tighten to the fasteners to 160 Nm (118 lb ft).

5. Install the drivetrain and front suspension frame reinforcements to the rear of the frame, then tighten the reinforcement fasteners to 22 Nm (16 lb ft).

Note:
Use the engine support fixture to slightly raise the powertrain assembly to aid in the installation of the engine and transmission mount bolts.

6. Install the engine support fixture. Refer to Engine Support Fixture Engine Support Fixture.





7. Install the transmission bracket mount to mount through bolt (1) and tighten to 100 Nm (74 lb ft).





8. Install the transmission mount through bolt (1) and tighten to 58 Nm (43 lb ft).

9. Install the engine mount. Refer to Engine Mount Replacement - Right Side Engine Mount Replacement - Right Side.





Warning:
Refer to Torque-to-Yield Fastener Warning Torque-to-Yield Fastener Warning.


10. Install the NEW left transmission mount to transmission bolts (1) and tighten to 50 Nm (37 lb ft) plus 60-75 degrees.





11. Install the inlet and outlet hose (2) to the steering gear (3).

12. Install power steering gear inlet and outlet hose bolts (1) and tighten to 11 Nm (97 lb in).





13. Instal NEW the lower steering intermediate shaft (1) bolt and tighten to 34 Nm (25 lb ft).

14. Connect the front steering knuckles to the strut assemblies. Refer to Steering Knuckle Replacement Service and Repair.





15. Install NEW the stabilizer link nut (1) to the strut assemblies. Refer to Stabilizer Shaft Link Replacement Front Suspension.

16. Connect the right wheel drive shaft from the intermediate shaft.





17. Install the front brake caliper (1) and tighten the brake caliper guide pin bolt (2) to 28 Nm (21 lb ft).

18. Install the exhaust system. Refer to Exhaust System Replacement Service and Repair.

19. Connect the wheel speed connectors to the steering knuckles.

20. Remove the engine support fixture.

21. Connect the wiring connectors and ground strap to the transmission.

22. Connect the wiring harness to the accessory wiring junction block.

23. Connect the electrical connectors to the ECM. Refer to Engine Control Module Replacement Service and Repair.





24. Install the wiring harnesses (2).

25. Install the ground nuts (1) and tighten to 9 Nm (80 lb in).





26. Connect the wiring harness plugs (1).





27. On vehicles equipped with a automatic transmission, connect the transmission range selector lever cable terminal (1) to the transmission manual shift lever pin.

28. On vehicles equipped with a automatic transmission, press the locking tabs outward in order to lock the transmission range selector lever cable (2) to the cable bracket.





29. On vehicles equipped with a manual transmission, connect the shift lever cables (2) to the shift levers (3)

30. On vehicles equipped with a manual transmission, install the shift lever cables (2) to the cable bracket (1).

31. Install the battery tray. Refer to Battery Tray Replacement Service and Repair.





32. Connect inlet (2) and outlet (1) heater core hoses.





33. Connect the power brake booster vacuum pipe (1).





34. Connect the coolant hose and reposition the clamp (1).





35. Connect the fuel feed line (1) and reposition away from the engine. Refer to Fuel Pressure Relief Service and Repair.





36. Connect the EVAP hose (1). Refer to Plastic Collar Quick Connect Fitting Service Service and Repair.





Note:
Use NEW O-ring seals. Refer to Air Conditioning O-Ring Seal Replacement Air Conditioning O-Ring Seal Replacement.

37. Install refrigerant hose (2) and tighten the nut (1) to 19 Nm (14 lb ft).

38. Install the charge air cooler inlet air hose. Refer to Charge Air Cooler Inlet Air Hose Replacement .

39. Install the charge air cooler outlet air hose. Refer to Charge Air Cooler Outlet Air Hose Replacement (Automatic Transmission) Charge Air Cooler Outlet Air Hose Replacement (Manual Transmission) .

40. Connect engine coolant hoses as necessary.

41. Connect electrical connectors as necessary.

42. Install the front fascia.

43. Install the front wheelhouse front liners.

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

45. Fill the engine cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (GE-47716 Fill) Cooling System Draining and Filling (GE-47716 Fill).

46. Charge the air conditioning system. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging.

47. Check engine oil level. Refer to Engine Oil and Oil Filter Replacement Service and Repair.

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