D. Engine Replacement (LD Model)
1. Remove the hood.2. Remove the cowl panel cover.
3. Remove the strut tower support and windshield wiper module (Figure 21).
4. Disconnect and isolate the negative battery cable, located in the trunk.
5. Perform the Refrigerant System Recovery procedure.
6. Lift the engine cover retaining grommets off the ball studs and remove the engine cover (Figure 21).
7. Remove the air cleaner assembly and throttle body air inlet hose (Figure 21).
8. Raise and support the vehicle.
9. Remove and save the underbody splash shield (Figure 22).
10. Drain the cooling system and engine oil.
11. For vehicles with All Wheel Drive (AWD), remove the front axle assembly.
12. Disconnect both the left and right upstream oxygen sensor electrical connectors.
13. Remove the exhaust down pipe to catalytic converter retaining nuts from both the left and right down pipes.
14. Remove and save the starter motor (Figure 23).
15. If the engine is seized, continue to Step 17.
16. Rotate the crankshaft in a clockwise direction until the torque converter bolts are accessible through the starter mounting hole in the transmission bellhousing. Remove the six torque converter bolts.
17. Lower the vehicle.
18. Remove the coolant bottle return hose.
19. Remove the heater core purge hose from the coolant bottle.
20. Remove and save the coolant bottle retaining bolts and coolant bottle (Figure 24).
21. Disconnect all accessible vacuum hoses from the engine.
22. Disconnect all electrical connectors from the engine.
23. Remove the fresh air makeup hose from the rear of the intake manifold.
24. Remove the upper intake manifold and insulator.
25. Disconnect the fuel supply hose from the underbody fuel supply tube (Figure 25).
26. Remove the cooling fan module (Figure 26).
27. Rotate the accessory drive belt tensioner counterclockwise until it contacts the stop and remove the accessory drive belt, then slowly rotate the tensioner into the free arm position.
28. Remove the generator.
29. Remove the ground strap from the right engine mount bracket.
30. Remove the upper radiator hose from the engine thermostat housing.
31. Remove the lower heater core return hose from the engine coolant pump housing.
32. Remove the lower radiator hose from the engine coolant pump housing.
33. Remove the heater core return tube lower support bracket retaining nut.
34. Disconnect the heater core return hose.
35. Remove the heater core return tube upper support bracket retaining nut and remove tube.
36. Remove the A/C compressor.
37. Raise and support the vehicle.
38. Unfasten the starter wire harness retainer and the main wire harness retainer from the engine block.
39. Remove the bolt and reposition the transmission cooling lines.
40. Disconnect all electrical connections from the engine accessible from under the vehicle.
41. Remove the two upper side transmission-to-engine retaining bolts.
42. Remove the side engine-to-transmission bolt.
43. Remove the transmission dust shield retaining bolt and remove the dust shield.
44. Remove and save the two rubber plugs covering the rear oil seal retainer flange bolts.
45. Remove and save the four transmission-to-the engine oil pan bolts.
46. Lower the vehicle.
47. Remove the two bolts and remove the heater core inlet tube.
48. Remove the bolt and remove the engine oil dipstick tube.
49. Remove the left intake manifold support bracket retaining bolts and remove the support brackets.
50. Install the left side engine lifting bracket 10242-1 on the left cylinder head with bolts provided with the engine lifting bracket and tighten bolts to 15 ft.lbs. (21 N.m).
51. Install the right side engine lifting bracket 10242-2 on the right cylinder head with bolts provided with the engine lifting bracket and tighten bolts to 15 ft. lbs. (21 N.m).
52. Position a load-leveling lifting sling, such as OTC(R) 4305 Engine Load Leveler or equivalent, between the engine lifting brackets and an engine hoist.
53. Reposition the starter wire harness and the main wire harness to the rear of the engine compartment.
54. Support the transmission with a suitable jack.
55. Remove the two upper transmission-to-engine retaining bolts and remove the electric vacuum pump.
56. Remove both the left and right engine mount lower retaining bolts.
57. Using an engine hoist, carefully remove the engine from the engine compartment (Figure 27).
58. Transfer all necessary components from the original engine to the replacement engine.
59. Remove and save the upper intake manifold from the replacement engine.
60. Transfer the engine lifting brackets (10242-1 and 10242-2) onto the replacement engine.
61. Carefully lower the replacement engine into the engine compartment while aligning the two locator dowels into the transmission housing. Install two bell housing bolts to hold engine against the transmission bellhousing.
62. Align the engine mounts, install both the left and right engine mount lower retaining bolts and tighten to 50 ft. lbs. (68 N.m).
63. Position the electric vacuum pump, install the two transmission to engine retaining bolts and tighten to 41 ft. lbs. (55 N.m).
64. Remove the engine lifting brackets and position the left upper intake manifold support brackets and install the retaining studs finger tight.
65. Route the main wire harness and starter wire harness on the engine.
66. Route the wiring harness and connect all electrical connections accessible from the top of the engine.
67. Connect all vacuum hoses accessible from the top of the engine.
68. Install the ground strap to the right engine mount bracket.
69. Remove the jack supporting the transmission.
70. Raise and support the vehicle.
71. Install the four transmission-to-the engine oil pan retaining bolts and tighten to 41 ft. lbs. (55 N.m).
72. Install the two rubber plugs covering the rear oil seal retainer flange bolts.
73. Install the side engine-to-transmission retaining bolt and tighten to 41 ft. lbs. (55 N.m).
74. Position the torque converter dust shield, install the retaining bolt and tighten to 12 N�m (9 ft. lbs.).
75. Install the two upper side transmission-to-engine retaining bolts and tighten to 55 N�m (41 ft. lbs.).
76. Connect the main harness to the engine oil pressure/temperature harness at the rear of the left cylinder head.
77. Rotate the crankshaft in a clockwise direction and install the six torque converter bolts through the starter mounting hole and tighten to 31 ft. lbs. (42 N.m).
78. Install the transmission cooling lines and tighten the bolt to 106 in. lbs. (12 N�m).
79. Secure the starter wire harness retainer and the main wire harness retainer to the engine block.
80. Install the starter motor.
81. Connect all engine electrical connectors accessible from under the vehicle.
82. If equipped with AWD, install the front axle assembly with propeller shaft, intermediate shaft, halfshafts, wheels and tires.
83. Position both left and right exhaust down pipes to the catalytic converters, install the retaining nuts and tighten to 22 ft. lbs. (30 N.m).
84. Install the underbody splash shield.
85. Lower the vehicle.
86. Connect the main harness to the engine injection/ignition harness at the rear of the left cylinder head.
87. Install the upper intake manifold and insulator.
88. Install the engine oil dipstick tube. Tighten the attaching bolt to 9 ft.lbs. (12 N.m).
89. Position the heater core inlet tube and install two bolts tightened to 9 ft.lbs. (12 N.m).
90. Install the A/C compressor.
91. Position the heater core return tube, install the upper support bracket retaining nut and tighten to 9 ft. lbs. (12 N.m).
92. Connect the heater core return hose.
93. Position the heater core return tube lower support bracket onto the A/C lower retaining stud, install the retaining nut and tighten to 9 ft. lbs. (12 N.m).
94. Install the lower heater core return hose to the engine coolant pump housing.
95. Install the lower radiator hose to the engine coolant pump housing.
96. Install the upper radiator hose to the engine thermostat housing.
97. Install the generator.
98. Rotate the accessory drive belt tensioner counterclockwise until it contacts the stop and install the accessory drive belt, then slowly rotate the tensioner into position.
99. Install the cooling fan module.
100. Connect the fuel supply hose to the underbody fuel supply tube.
101. Connect the fresh air makeup hose to the rear of the intake manifold.
102. Install the coolant bottle. Tighten the retaining bolts to 9 ft. lbs. (12 N.m).
103. Install the air cleaner housing. Tighten the retaining bolt to 9 ft. lbs. (12 N.m).
104. Connect the fresh air makeup hose to the air cleaner housing.
105. Install the strut tower support.
106. Install the windshield wiper module.
107. Install the cowl panel cover.
108. Install the hood.
109. Fill the cooling system with engine coolant.
110. Perform the Refrigerant System Charge procedure.
111. Position the engine cover and secure the retaining grommets onto the ball studs.
112. Connect the negative battery cable and tighten nut to 45 in. lbs. (5 N.m).
113. Check and fill engine oil as required.
114. Start engine and allow it to warm up. Then check the coolant level.
115. For seized engines, check the transaxle fluid level.
116. Connect the wiTECH scan tool and erase any Diagnostic Trouble Codes.