Engine Replacement

Engine Replacement

Special Tools

* BO-38185 - Hose Clamp Pliers

* CH-24319-B - Steering Linkage and Tie Rod Puller

* J-43828 - Ball Joint Separator

* J-44015 - Steering Linkage Installer

For equivalent regional tools, refer to Special Tools Special Tools.

Removal Procedure

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





2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Service and Repair.

3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement.

4. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement Service and Repair.

5. Disconnect the fuel feed pipe (1) quick connect fitting at the fuel rail. Refer to Metal Collar Quick Connect Fitting Service Service and Repair.

6. Disconnect the evaporative emission (EVAP) line (3) quick connect fitting from the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service Service and Repair.

7. Remove the fuel feed pipe clip (2) from the fuel line bracket.

8. Remove the intake manifold. Refer to Intake Manifold Replacement Intake Manifold Replacement.

9. Remove the engine control module cover and disconnect electrical connectors.

10. Remove the accessory wiring junction block, disconnect and reposition wiring harness to engine. Refer to Accessory Wiring Junction Block Replacement Accessory Wiring Junction Block Replacement.

11. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (LEA) Service and Repair.

12. Remove the oxygen sensors. Refer to Heated Oxygen Sensor Replacement - Sensor 1 Heated Oxygen Sensor Replacement - Sensor 1 and Heated Oxygen Sensor Replacement - Sensor 2 Heated Oxygen Sensor Replacement - Sensor 2.

13. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.

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

15. Drain the cooling system. Refer to Cooling System Draining and Filling (GE 47716) Cooling System Draining and Filling (GE 47716)Cooling System Draining and Filling (Static LF1 or LFW) Cooling System Draining and Filling (Static)Cooling System Draining and Filling (Static LAF or LEA) Cooling System Draining and Filling (Static).

16. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement Service and Repair.

17. Lower the vehicle.





18. Reposition the vacuum brake booster hose clamp (1) at the intake manifold.

19. Remove the vacuum brake booster hose (2) from the intake manifold. Reposition the brake booster hose out of the way.





20. Remove the coolant recovery inlet hose clamp (2) at the cylinder head.

21. Remove the coolant recovery inlet pipe from the fuel pump cover.

22. Remove the coolant recovery inlet hose (1) from the cylinder head. Reposition the hose/pipe out of the way.





23. Reposition the radiator inlet hose clamp using the BO-38185 - pliers.

24. Remove the radiator inlet hose from the cylinder head.

25. Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (LF1 or LFW) Radiator Outlet Hose ReplacementRadiator Outlet Hose Replacement (LEA) Radiator Outlet Hose Replacement.





26. Reposition the heater inlet hose clamp at the thermostat housing.

27. Remove the heater inlet hose from the thermostat housing.

28. Remove the heater outlet hose clamp and hose at thermostat housing.

29. Reposition the coolant recovery reservoir/heater inlet hose (2) clamp at the thermostat housing.

30. Remove the coolant recovery reservoir/heater inlet hose (2) from the thermostat housing.

31. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.

32. Disconnect the engine wiring harness electrical connector from the air conditioning (A/C) compressor.





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

34. Remove the negative battery cable lead from the transaxle stud. Reposition the negative battery cable out of the way.

35. Remove the starter. Refer to Starter Replacement (LFW) Service and RepairStarter Replacement (LAF or LEA) Service and Repair.

36. Lower the vehicle.





37. Remove the transaxle shift cable from the range select lever.

38. 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.

39. Using long tie straps, secure the radiator/condenser/fan assembly to the radiator support.

40. Raise the vehicle.

41. Remove the left engine splash shield. Refer to Engine Splash Shield Replacement - Left Side Engine Splash Shield Replacement - Left Side

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

42. Install a piece of hardwood 1 x 2 x 4 between the transaxle and the engine cradle.

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

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





44. Drain the transaxle fluid.

45. Remove the transaxle oil cooler line to transaxle nut (1).

46. Remove the transaxle oil cooler lines from the transaxle.

47. Remove the catalytic converter. Refer to Catalytic Converter Replacement (LEA-FWD) Catalytic Converter Replacement (FWD)Catalytic Converter Replacement (LEA-AWD) Catalytic Converter Replacement (AWD).





Note:
Secure the steering wheel in the straight forward position before separating the intermediate shaft from the steering gear, or damage to the SIR coil will occur.

48. Remove the intermediate to steering gear pinch bolt and disconnect the intermediate shaft from the steering gear. Discard the pinch bolt.





49. Remove and discard both outer tie rod to steering knuckle nuts.

Note:
Hold the ball stud to prevent turning during removal of the nut.

50. Use the CH-24319-B - puller.





51. Remove the stabilizer link to stabilizer shaft nuts and disconnect the stabilizer links from the stabilizer shaft.





52. Remove and discard both of the lower control arm ball stud cotter pins.

53. Loosen the ball stud nuts until the nuts are level with the top of the ball stud.





54. Use the J-43828 - separator.

55. Remove the ball stud nuts.

56. Remove the wheel drive shafts. Refer to Front Wheel Drive Shaft Replacement Front Wheel Drive Shaft Replacement.

57. Lower the vehicle.





58. Remove the engine mount to engine mount bracket bolts (2).





59. Remove the transaxle mount to transaxle adapter bolts.

60. Disconnect electrical connectors and harnesses as necessary.

61. Raise the vehicle.





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

62. Position a 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.

63. With the table positioned, fully raise the table to contact with the powertrain assembly.

64. Remove the frame to body bolts. Discard the bolts.

Note:
When lowering the engine/transaxle assembly, verify all brake lines, shifter cables and other components are free during removal.

65. Lower the engine table and raise the body on the hoist until the engine/transaxle and cradle are free from the vehicle.





66. Remove the torque converter to flexplate bolts (1).

67. Disconnect the electrical harnesses as necessary.

68. Install a suitable lifting devise to the engine.





69. Remove the transaxle bolts from the engine.

70. Separate the engine from the transaxle.

71. Install the engine to a suitable engine stand.

Installation Procedure





1. Install a suitable lifting devise to the engine.

2. Using the lifting devise, 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 the bolts to 75 Nm (55 lb ft).





4. Install the torque converter to flexplate bolts (1) and tighten to 62 Nm (46 lb ft).

5. Connect the electrical harnesses as necessary.

6. Remove the engine lifting devise.





7. Position the powertrain and support table under the vehicle.

8. Raise the powertrain into position under the vehicle.

9. With the table positioned, if required, lower the vehicle over the powertrain.

10. 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.

11. Install the NEW frame to body bolts and tighten to 155 Nm (114 lb ft).

12. Lower the vehicle.





13. Install the transaxle mount to transaxle adapter bolts and tighten to 50 Nm (37 lb ft).





14. Install the engine mount to engine mount bracket bolts (2).

15. Tighten the engine mount to bracket bolts in the following sequence:

1. Middle

2. Rear

3. Front

Tighten the bolts to 58 Nm (43 lb ft).

16. Raise and support the vehicle.

17. Install the wheel drive shafts. Refer to Front Wheel Drive Shaft Replacement Front Wheel Drive Shaft Replacement.





18. Install the control arm ball studs into the steering knuckles.

19. Install the ball stud nuts and tighten to 10 Nm (89 lb in) plus 165 degrees.

20. Continue to tighten the nuts only enough to align the castle nut slots with the ball stud, install NEW cotter pins.





21. Connect the stabilizer links to the stabilizer shaft and install the stabilizer link to stabilizer shaft nuts. Tighten the nuts to 85 Nm (63 lb ft).





22. Connect the outer tie rods to the steering knuckles.

23. Use the J-44015 - installer.

24. Remove the J-44015 - installer.





25. Install NEW outer tie rod to steering knuckle nuts and tighten to 25 Nm (18 lb ft) plus 90 degrees.





26. Position the intermediate shaft to the steering gear and install a NEW pinch bolt.

Tighten the bolt to 36 Nm (27 lb ft).

27. Install the catalytic converter. Refer to Catalytic Converter Replacement (LEA-FWD) Catalytic Converter Replacement (FWD)Catalytic Converter Replacement (LEA-AWD) Catalytic Converter Replacement (AWD).





28. Install the transaxle oil cooler lines to the transaxle.

29. Install the transaxle oil cooler line to transaxle nut (1) and tighten to 22 Nm (16 lb ft).





30. Remove the wood from between the oil pan and the engine cradle.

31. Remove the wood from between the transaxle and the engine cradle.

32. Install the engine splash shield. Refer to Engine Splash Shield Replacement - Left Side Engine Splash Shield Replacement - Left Side.

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

34. Lower the vehicle.





35. Unsecure and position the radiator/condenser/fan assembly.





36. Install the shift control cable to the shift control cable bracket and engage the shift control cable retaining clip.

37. Install the transaxle shift cable to the range select lever.

38. Raise and support the vehicle.

39. Install the oxygen sensors. Refer to Heated Oxygen Sensor Replacement - Sensor 1 Heated Oxygen Sensor Replacement - Sensor 1 and Heated Oxygen Sensor Replacement - Sensor 2 Heated Oxygen Sensor Replacement - Sensor 2.

40. Instal the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement (LEA) Service and Repair.

41. Install the engine control module. Refer to Engine Control Module Replacement Service and Repair.

42. Install the starter. Refer to Starter Replacement (LFW) Service and RepairStarter Replacement (LAF or LEA) Service and Repair.





43. Position the negative battery cable and install the negative battery cable lead (2) to the transaxle stud.

44. Install the engine wiring harness ground lead nut (1) to the transaxle stud and tighten the nut to 50 Nm (37 lb ft).





45. Position the A/C compressor and install the bolts and tighten to 22 Nm (16 lb ft).

46. Connect the engine wiring harness electrical connector to the A/C compressor.

47. Lower the vehicle.





48. Install the coolant recovery reservoir/heater inlet hose (2) to the thermostat housing.

49. Position the coolant recovery reservoir/heater inlet hose (2) clamp at the thermostat housing.

50. Install the heater inlet hose (3) to the thermostat housing.

51. Position the heater inlet hose clamp at the thermostat housing.





52. Connect the radiator inlet hose to the cylinder head.

53. Reposition the radiator inlet hose clamp using the BO-38185 - pliers.

54. Connect the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (LF1 or LFW) Radiator Outlet Hose ReplacementRadiator Outlet Hose Replacement (LEA) Radiator Outlet Hose Replacement.





55. Position and install the coolant recovery inlet hose (1) to the cylinder head.

56. Install the coolant recovery inlet pipe to the fuel pump cover.

57. Install the coolant recovery inlet hose clamp (2) at the cylinder head.





58. Position and install the vacuum brake booster hose (2) to the intake manifold.

59. Position the vacuum brake booster hose clamp (1) at the intake manifold.





60. Install the intake manifold. Refer to Intake Manifold Replacement Intake Manifold Replacement.

61. Install the fuel feed pipe clip (2) to the fuel line bracket.

62. Connect the EVAP line (3) quick connect fitting to the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service Service and Repair.

63. Connect the fuel feed pipe (1) quick connect fitting at the fuel rail. Refer to Metal Collar Quick Connect Fitting Service Service and Repair.

64. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement.

65. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement Service and Repair.

66. Fill the cooling system. Refer to Cooling System Draining and Filling (GE 47716) Cooling System Draining and Filling (GE 47716)Cooling System Draining and Filling (Static LF1 or LFW) Cooling System Draining and Filling (Static)Cooling System Draining and Filling (Static LAF or LEA) Cooling System Draining and Filling (Static).

67. Fill the transaxle with fluid. Refer to Transmission Fluid Drain and Fill Transmission Fluid Drain and Fill.

68. Refill the engine with oil. Refer to Engine Oil and Oil Filter Replacement Service and Repair.

69. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn Testing and Inspection.

70. Start the engine and allow the engine to run, inspect for leaks. Correct as necessary.