C. Engine Replacement (Jc/Js/Rt Models)

1. Disconnect and isolate the negative battery cable.

2. Raise and support the vehicle.





3. Remove the underbody splash shield (Figure 9).

4. Drain the cooling system and engine oil.

5. Lower the vehicle.

6. Remove and save the engine cover.

7. Recover the refrigerant from the refrigerant system.

8. Remove and save the air cleaner body and resonator





9. Remove and save the electric vacuum pump and mounting bracket (Figure 10).

10. Remove and save the coolant recovery bottle.

11. Disconnect the fuel line from the fuel rail inlet.

12. Disconnect the heater core supply and return hoses.

13. Remove and save the nut, bolt and the heater core return tube.

14. Disconnect all accessible vacuum hoses from the engine.

15. Remove and save the upper intake manifold.

16. Disconnect the upper radiator hose from the engine.

17. Remove and save the cooling fan module.

18. Remove and save the accessory drive belt.

19. Remove and save the generator.

20. Disconnect all electrical connectors accessible from the top side of the engine.

21. Raise and support the vehicle.

22. Remove and save both front tire and wheel assemblies.

23. Remove and save the left and right lower splash shield.

24. Remove and save both axle shafts and the intermediate shaft.





25. Remove and save the front fore and aft crossmember (Figure 11).





26. Remove and save the cross-under pipe (Figure 12).

27. Disconnect the oxygen sensor connectors from the main wire harness and remove both catalytic converters.

28. If equipped with AWD, remove and save the Power Takeoff Unit (PTU).




29. Remove and save the three bolts and the front engine mount bracket (Figure 13).





30. Remove and save the starter motor (Figure 14).

31. Disconnect the lower radiator hose from the engine.

32. Remove and save the A/C compressor from the engine compartment.

33. For Front Wheel Drive (FWD) vehicles, remove two bolts and the rear engine mount heat shield.

34. Push back the heat shield from the crankshaft position sensor and disconnect the crankshaft position sensor electrical connector.

35. Disengage one wire harness retainer from the engine block and one wire harness retainer from the transmission mounting stud.

36. For FWD vehicles, disengage the downstream oxygen sensor connector from the engine mount.

37. If equipped with a block heater, disconnect and reposition the power cord from the engine block heater.

38. Disengage the wire harness retainer from the power steering pump.

39. Remove and save the three mounting bolts and reposition the power steering pump and bracket as an assembly. Do not disconnect the power steering lines from the pump.

40. Disconnect the oil pump solenoid electrical connector.

41. Disengage the wire harness retainer from the engine block.

42. Disengage the three main wire harness retainers from the right cylinder head cover.

43. For FWD vehicles, remove five bolts and remove the rear engine mount bracket.

44. If equipped with AWD, remove the rear engine mount bracket and isolator assembly.





45. Remove the transaxle torque converter housing dust cover and rubber plugs (Figure 15).

46. Remove and discard the torque converter-to-drive plate bolts. Upon removing the bolts, a tight-tolerance (slotted) bolt will be encountered. Mark this location (flex plate and converter) with paint for assembly reference.

47. Remove and save the four transaxle-to-engine lower bolts.

48. Lower the vehicle.

49. Disconnect the transmission solenoid harness connector.

50. Disengage the main wire harness retainer from the transmission valve body pan.

51. Disconnect the transmission input shaft speed sensor connector.





52. Disconnect the oil cooler lines from transaxle using Special Tool 8875A (Figure 16).

53. Disconnect the gearshift cable from the transaxle manual valve lever and cable mounting bracket.

54. Disconnect the two output shaft speed sensors connectors.

55. Disengage the wire harness retainer from the gearshift cable bracket. Figure 16 Transaxle Oil Cooler Lines

56. Reposition the main wire harness away from the engine.

57. Raise and position the vehicle height to allow Powertrain Dolly 6135 and Engine Support Cradle 6710A to be installed under the engine/transaxle assembly.

58. Loosen the cradle engine mounts to allow movement for positioning onto the engine locating holes on the engine block and oil pan rail. Place Adapter 6848-3 on the front post and align to the oil pan mounting stud. Lower the vehicle and position cradle until the engine is resting on the posts. Tighten the post mounts to the cradle frame. Secure the engine/transaxle assembly to the dolly/cradle with safety straps.

59. Lower the vehicle so that the weight of the engine and transmission ONLY is on the cradle.





60. Remove and save the three bolts from the right engine mount bracket (Figure 17).





61. Remove and save the two bolts from the left transaxle mount bracket (Figure 18).





62. Slowly raise the vehicle in short length spans. Inspect at each interval for potential engine or transaxle contact to vehicle components (Figure 19). Move the cradle/dolly fixture as necessary to allow for removal clearance.

63. Position a transmission jack under the transaxle. Secure the transaxle to the transmission jack.

64. Remove and save the remaining six transaxle upper bellhousing-to�block bolts.

65. Separate the transaxle from the engine.

66. Remove and save the bolts and remove the upper intake manifold support brackets.

67. Remove and save the two bolts and the heater core supply tube.





68. Install the Driver Side Engine Lifting Bracket 10242-1 on the left cylinder head with bolts provided with the Engine Lifting Bracket (Figure 20). Tighten the bolts to 15 ft. lbs. (21 N.m).

69. Install the Passenger Side Engine Lifting Bracket 10242-2 on the right cylinder head with bolts from the Engine Lifting Bracket (Figure 20). Tighten the bolts to 15 ft. lbs. (21 N.m).

70. 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.

71. Remove the engine from the cradle/dolly fixture.

72. Carefully remove and save the intake manifold from the replacement engine.

73. Transfer engine lifting brackets (10242-1 and 10242-2) onto the replacement engine.

74. For seized engines only, pour one quart of transmission fluid into the new torque converter and install the torque converter into the transmission.


75. Install the transaxle to the engine. Secure with six transaxle upper bellhousing-to-block bolts and tighten to 52 ft.lbs. (70 N.m).

76. Position the engine/transaxle assembly on the Powertrain Dolly 6135 and Engine Support Cradle 6710A.

77. Loosen the cradle engine mounts to allow movement for positioning onto the engine locating holes on the engine block and oil pan rail. Place Adapter 6848-3 on the front post and align to the oil pan mounting stud. Tighten the post mounts to the cradle frame. Secure the engine/transaxle assembly to the dolly/cradle with safety straps. Remove both engine lifting brackets.

78. Transfer all necessary components from the original engine to the replacement engine.

79. Position the engine/transaxle assembly under the vehicle. Slowly lower the vehicle in short length spans. Inspect at each interval for potential engine or transaxle contact to vehicle components. Move the cradle/dolly fixture as necessary to allow for clearance.

80. Install the three bolts to the right engine mount bracket and tighten bolts to 41 ft. lbs. (55 N.m).

81. Install the two bolts to the left engine (transmission) mount bracket.

82. Remove the engine safety strap, raise the vehicle slightly and remove the powertrain dolly from under the vehicle.

83. Lower the vehicle and connect all accessible electrical connectors.

84. Connect the gearshift cable to the mounting bracket and transaxle manual valve lever.

85. Connect the oil cooler lines to the transaxle.

86. Raise and support the vehicle.

87. Install the four transaxle-to-engine lower bolts and tighten to 52 ft. lbs. (70 N.m).

88. Install the torque converter-to-drive plate bolts and tighten to 65 ft. lbs. (88 N.m).

89. Install the transaxle torque converter housing dust cover and rubber plugs.

90. For FWD vehicles, install the rear engine mount bracket and the bolts to 81 ft. lbs. (110 N.m).

91. If equipped with AWD, install the bolt to the rear engine mount isolator and tighten to 44 ft. lbs. (60 N.m).

92. Lower the vehicle.

93. Install the heater core supply tube with two bolts and tighten to 106 in. lbs. (12 N.m).

94. Install the left upper intake manifold support brackets. Loosely install the stud bolts.

95. Engage three main wire harness retainers to the right cylinder head cover.

96. Raise and support the vehicle.

97. Connect the oil pump solenoid electrical connector.

98. Engage the wire harness retainer to the engine block.

99. Install the power steering pump and bracket as an assembly with three bolts and tighten to 18 ft. lbs. (25 N.m).

100. Engage the wire harness retainer to the power steering pump.

101. Install the power steering pump heat shield. Tighten bolts to 18 ft. lbs. (25 N.m).

102. For vehicles with a block heater, connect the power cord to the engine block heater.

103. Connect all underbody electrical connectors and wiring harness retainers.

104. For FWD vehicles, install the rear engine mount heat shield. Tighten bolts to 124 in. lbs. (14 N.m).

105. Install the A/C compressor. Install and tighten the two bolts and two nuts in the following sequence:

a. Install all bolts and nuts hand tight.

b. Tightened upper nut to 30 ft. lbs. (40 N.m).

c. Tightened lower nut to 30 ft. lbs. (40 N.m).

d. Tightened upper bolt to 17 ft. lbs. (23 N.m).

e. Tightened lower bolt to 17 ft. lbs. (23 N.m).

106. Install the lower radiator hose.

107. Place the starter motor into position and install the starter motor retaining bolts. Tighten the bolts to 40 ft. lbs. (55 N.m).

108. Install the front engine mount bracket. Tighten bolts to 40 ft. lbs. (55 N.m).

109. If equipped with AWD, install the Power Take Off Unit (PTU).

110. Install both catalytic converters using the following process:

a. If new gaskets need replacing, position new gasket onto the manifold flange and install the lower retainer plate. Loosely install all four bolts to align the gasket. Tighten lower retainer bolts to 27 ft. lbs. (37).

b. Position the catalytic converter against the exhaust manifold. Position the converter flange to the retainer.

c. Install the upper flange bolts. Tighten upper bolts to 27 ft. lbs. (37 N.m).

111. Connect the oxygen sensor connectors to the main wire harness.

112. Install the cross-under pipe using the following procedure:

a. Position new gaskets onto the catalytic converter flanges.

b. Position the cross-under pipe into its position between the catalytic converters.

c. Install the front flange mounting nuts. Tighten the nuts to 250 in. lbs. (28 N.m).

d. Install the rear flange bolts. Tighten the bolts to 22 ft. lbs. (30 N.m).

e. Install the cross-under support bolts. Tighten the nuts to 250 in. lbs. (28 N.m).

113. Install the front fore and aft crossmember using the following procedure:

a. Position fore-aft crossmember in engine compartment and install mounting bolts.

b. Tighten forward mounting bolts to 83 ft. lbs. (113 N.m).

c. Tighten rearward mounting bolts at suspension crossmember to 41 ft. lbs. (55 N.m).

114. Install the right side intermediate shaft and then both axle shafts using the following procedure:

a. Install the intermediate shaft into position.

b. Install the three bolts holding the mid-shaft bearing to the block and tighten to 39 ft. lbs. (54 N.m).

c. Install the tripod joint into the transaxle side gear as far as possible by hand. Be sure to engage splines prior to applying force.

d. Forcefully push the tripod joint onto the intermediate shaft, until the snap-ring is engaged.

e. Install the half shaft into the hub/bearing assembly.

f. Install and tighten the hub nut to 118 ft. lbs. (160 N.m).

115. Install the generator and tighten the generator mounting retainers to 18 ft. lbs. (25 N.m).

116. Install the accessory drive belt.

117. Install the right and left lower splash shields.

118. Install both front tire and wheel assemblies.

119. Install the underbody splash shield.

120. Lower the vehicle.

121. Connect all accessible vacuum hose to the engine.

122. Connect the heater core supply and return hoses.

123. Install the cooling fan module.

124. Install the upper intake manifold.

125. Install the upper radiator hose and engage the hose retainer to the intake manifold.

126. Install the coolant recovery bottle.

127. Connect the fuel line to the fuel rail inlet tube.

128. Install the air cleaner body and resonator.

129. Install the electric vacuum pump and mounting bracket.

130. Recharge air conditioning system.

131. Fill the cooling system.

132. Install the engine cover.

133. For all models except JS, install the fuel pump fuse.

134. For JS models, connect the wiring harness to the fuel pump module.

135. For JS models, install the black plastic access plug, sound deadening pad and rear seat.

136. Check the engine oil level and fill if required.

137. Connect the negative battery cable and tighten nut to 45 in. lbs. (5 N.m).

138. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level.

139. For vehicles with a seized engine, check transmission fluid level and add as required.

140. Connect the wiTECH scan tool and erase any Diagnostic Trouble Codes (DTC's).