Engine Replacement

Engine Replacement

Removal Procedure

1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement Fuel Injector Sight Shield Replacement.




2. Disconnect the brake booster vacuum hose (2) from the intake manifold.

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

4. Discharge the fuel system. Refer to Fuel Pressure Relief (Without CH-48027) Fuel Pressure Relief (Without CH-48027)Fuel Pressure Relief (CH-48027) Fuel Pressure Relief (CH-48027)Fuel Pressure Relief (High Side) Fuel Pressure Relief (High Side).




5. Disconnect the evaporative emission (EVAP) hose/pipe (3) from the EVAP canister purge solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service Service and Repair.




6. Disconnect the engine fuel hose/pipe (3) from the chassis fuel hose/pipe (2). Refer to Metal Collar Quick Connect Fitting Service Service and Repair.

7. Discharge the air conditioning (A/C) system. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging.




8. Remove the A/C compressor hose assembly (2) from the compressor. Cap or plug the hoses and compressor to prevent contamination. Refer to Air Conditioning Compressor Hose Replacement Air Conditioning Compressor Hose Replacement.

9. Drain the engine coolant from the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (Vac N Fill) Cooling System Draining and Filling (Vac N Fill).

10. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement Service and Repair.

11. Disconnect the inlet coolant heater hose from the engine. Refer to Heater Inlet Hose Replacement Heater Inlet Hose Replacement.

12. Disconnect the outlet coolant heater hose from the engine. Refer to Heater Outlet Hose Replacement Heater Outlet Hose Replacement

13. Remove the radiator inlet hose. Refer to Radiator Inlet Hose Replacement Radiator Inlet Hose Replacement.

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

15. Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement Radiator Outlet Hose Replacement.

16. Remove the exhaust flexible pipe and secure the rear half of the exhaust system to the vehicle underbody. Refer to Exhaust Flexible Pipe Replacement Service and Repair.

17. Remove the front tires. Refer to Tire and Wheel Removal and Installation Removal and Replacement.




18. Remove the steering intermediate shaft pinch bolt (1) in order to disconnect the steering intermediate shaft from the steering gear.




19. Disconnect the transaxle shift cable (2). Refer to Range Selector Lever Cable Replacement Range Selector Lever Cable Replacement.

20. Disconnect the transaxle cooler lines. Refer to Fluid Cooler Inlet Hose Replacement Fluid Cooler Inlet Hose Replacement and Fluid Cooler Outlet Hose Replacement Fluid Cooler Outlet Hose Replacement.

21. Disconnect the negative battery extension cable. Refer to Battery Negative Cable Extension Cable Replacement Battery Negative Cable Extension Cable Replacement.

22. Disconnect all engine electrical connectors.




23. Remove the right and left steering linkage outer tie rod ends from the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement Steering Linkage Outer Tie Rod Replacement.




24. Remove the right and left stabilizer shaft links from the stabilizer shaft. Refer to Stabilizer Shaft Link Replacement Front Suspension.




25. Remove the right and left lower ball joints from the steering knuckles. Refer to Lower Control Arm Replacement Front Suspension.

26. Place a drain pan under the transaxle then separate the right and left front wheel drive shafts from the transaxle/transfer case. Refer to Front Wheel Drive Shaft Replacement Front Wheel Drive Shaft Replacement.




27. On all wheel drive (AWD) models, remove the propeller shaft retaining bolts (1) in order to remove the shaft. Refer to Propeller Shaft Replacement Removal and Replacement.

28. Remove the engine mount strut. Refer to Engine Mount Strut Replacement - Right Side Engine Mount Strut Replacement - Right Side.




29. Disconnect the power steering hoses at the power steering fluid cooler (1). Refer to Power Steering Cooler Pipe/Hose Replacement Power Steering Cooler Pipe/Hose Replacement.

30. Place a universal frame support fixture or jackstands under the frame.

31. Lower the vehicle until the frame contacts the frame support fixture or jackstands.




32. Remove the subframe to body bracket bolts.




33. Remove the frame-to-body bolts (1).

Important: Inspect for areas of body to powertrain contact or entanglement of wires and hoses while separating the vehicle body and powertrain.


34. Carefully raise the vehicle body up away from the powertrain.




35. Disconnect the engine electrical wiring harness from the following components:

* Oxygen sensor (1)

* EVAP purge solenoid (2)

* Ignition coils (3, 4, 10)

* Ground lead (7)

* Remove wire harness from retainers (5, 6, 8, 9)




36. Disconnect the left and right cylinder head engine electrical wiring harness from the following components:

* Camshaft position sensors (1)

* Camshaft position actuators (2)




37. Disconnect the engine electrical wiring harness from the following components:

* Generator (1)

* Retainer clips (2, 3, 4, 5, 6, 7, 9)

* A/C compressor hose (8)

* Oil pressure switch (10)

* A/C compressor (8)




38. Disconnect the engine electrical wiring harness from the following components:

* Battery cable

* Retainer clips (2)

* Transmission module (1)

39. If equipped with an engine coolant heater, disconnect the coolant heater cord.

40. Remove the throttle body assembly. Refer to Throttle Body Assembly Replacement Removal and Replacement.




41. On FWD vehicles, remove the engine-to-transaxle brace bolts and brace.

42. On AWD vehicles, perform the following:

1. Remove the engine rear mount bracket. Refer to Engine Rear Mount Bracket Replacement (Front Wheel Drive) Engine Rear Mount Bracket Replacement (Front Wheel Drive)Engine Rear Mount Bracket Replacement (All Wheel Drive) Engine Rear Mount Bracket Replacement (All Wheel Drive).

2. Remove the transfer case. Refer to Transfer Case Assembly Replacement .




43. Remove the starter motor (2). Refer to Starter Replacement Service and Repair.




44. Remove the torque converter bolts (1).

45. Using a engine hoist and lift chain, support the engine weight.

46. Support the bellhousing of the transmission with a block of wood.




47. Remove the automatic transaxle bolts (1, 2).

48. Remove the front and rear engine mount to mount bracket nuts.

49. Separate the automatic transaxle from the engine.




50. Lift the engine (1) away from the frame and the automatic transaxle (2).

51. Secure the engine to an engine stand.

52. Remove any additional engine components as necessary. Refer to appropriate component sections in manual if needed.

Installation Procedure

1. Using a engine hoist and lift chain, remove the engine from the engine stand.




2. Align the engine (1) to the frame and automatic transaxle (2).





Caution: Refer to Fastener Caution Fastener Caution.

3. Install the automatic transaxle bolts (1, 2) and tighten to 75 Nm (55 lb ft).

4. Remove the engine hoist and lift chain.

5. Install the front and rear engine mount to bracket nuts, and tighten to 50 Nm (37 lb ft).




6. Install the torque converter bolts (1) and tighten to 60 Nm (44 lb ft).




7. Install the starter motor (2). Refer to Starter Replacement Service and Repair.




8. On FWD vehicles, install the engine to transaxle brace and bolts and tighten to 50 Nm (37 lb ft).

9. On AWD vehicles, perform the following:

1. Install the transfer case. Refer to Transfer Case Assembly Replacement .

2. Install the engine rear mount bracket. Refer to Engine Rear Mount Bracket Replacement (Front Wheel Drive) Engine Rear Mount Bracket Replacement (Front Wheel Drive)Engine Rear Mount Bracket Replacement (All Wheel Drive) Engine Rear Mount Bracket Replacement (All Wheel Drive).

10. Install the throttle body assembly. Refer to Throttle Body Assembly Replacement Removal and Replacement.

11. If equipped with an engine coolant heater, connect the coolant heater cord.




12. Connect the engine electrical wiring harness to the following components:

* Transmission module (1)

* Retainer clips (2)

* Battery cable

13. Install the battery cable to the cylinder head and tighten the bolt to 25 Nm (18 lb ft).




14. Connect the engine electrical wiring harness to the following components:

* A/C compressor (8)

* Oil pressure switch (10)

* A/C compressor hose (8)

* Retainer clips (2, 3, 4, 5, 6, 7, 9)

15. Install the Generator terminal connector and nut (1) and tighten to 13 Nm (115 lb in).




16. Connect the left and right cylinder head engine electrical wiring harness to the following components:

* Camshaft position actuators (2)

* Camshaft position sensors (1)




17. Connect the engine electrical wiring harness to the following components:

* Install wire harness to retainers (5, 6, 8, 9)

* Ground lead (7)

* Ignition coils (3, 4, 10)

* EVAP purge solenoid (2)

* Oxygen sensor (1)





Note: Front end alignment not required due to frame only being lowered and reinstalled.

18. Install the frame-to-body bolts (1) and tighten to 100 Nm (74 lb ft) + 90 degrees.




19. Install the subframe to body bracket bolts and tighten to 60 Nm (44 lb ft).

20. Raise the vehicle and remove the support fixture or jackstands from under the vehicle.




21. Connect the power steering hoses to the power steering fluid cooler (1). Refer to Power Steering Cooler Pipe/Hose Replacement Power Steering Cooler Pipe/Hose Replacement.

22. Install the left transaxle mount bracket. Refer to Transmission Mount Bracket Replacement - Left Side Transmission Mount Bracket Replacement - Left Side.

23. Install the engine mount strut. Refer to Engine Mount Strut Replacement - Right Side Engine Mount Strut Replacement - Right Side.

24. Raise the vehicle.




25. On AWD models, install the propeller shaft and retainers (1). Refer to Propeller Shaft Replacement Removal and Replacement.

26. On FWD models, install the right and left front wheel drive shafts into the transaxle. Refer to Front Wheel Drive Shaft Replacement Front Wheel Drive Shaft Replacement.




27. On all models, install the right and left lower ball joints to the steering knuckles. Refer to Lower Control Arm Replacement Front Suspension.




28. Install the right and left stabilizer shaft links to the stabilizer shaft. Refer to Stabilizer Shaft Link Replacement Front Suspension.




29. Install the right and left steering linkage outer tie rod ends to the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement Steering Linkage Outer Tie Rod Replacement.

30. Connect all engine electrical connectors.

31. Connect the negative battery extension cable. Refer to Battery Negative Cable Extension Cable Replacement Battery Negative Cable Extension Cable Replacement.




32. Connect the transaxle shift cable (2). Refer to Range Selector Lever Cable Replacement Range Selector Lever Cable Replacement.

33. Connect the transaxle cooler lines. Refer to Fluid Cooler Inlet Hose Replacement Fluid Cooler Inlet Hose Replacement and Fluid Cooler Outlet Hose Replacement Fluid Cooler Outlet Hose Replacement.




34. Connect the steering intermediate shaft to the steering gear and install the pinch bolt (1). Refer to Intermediate Steering Shaft Replacement Intermediate Steering Shaft Replacement.

35. Install the front tires. Refer to Tire and Wheel Removal and Installation Removal and Replacement.

36. Install the exhaust flexible pipe. Refer to Exhaust Flexible Pipe Replacement Service and Repair.

37. Install the radiator outlet hose. Refer to Radiator Outlet Hose Replacement Radiator Outlet Hose Replacement.

38. Lower the vehicle.

39. Install the radiator inlet hose. Refer to Radiator Inlet Hose Replacement Radiator Inlet Hose Replacement.

40. Connect the outlet coolant heater hose to the engine. Refer to Heater Outlet Hose Replacement Heater Outlet Hose Replacement

41. Connect the inlet coolant heater hose to the engine. Refer to Heater Inlet Hose Replacement Heater Inlet Hose Replacement.

42. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement Service and Repair.




43. Install the A/C compressor hose assembly (2) to the compressor. Refer to Air Conditioning Compressor Hose Replacement Air Conditioning Compressor Hose Replacement.




44. Connect the engine fuel hose/pipe (3) to the chassis fuel hose/pipe (2). Refer to Metal Collar Quick Connect Fitting Service Service and Repair.




45. Connect the EVAP hose/pipe (3) to the EVAP canister purge solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service Service and Repair.

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




47. Connect the brake booster vacuum hose (2) to the intake manifold.

48. Position the clamp (1) on the brake booster vacuum hose connection.

49. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement Fuel Injector Sight Shield Replacement.

50. Fill the engine with engine oil. Refer to Approximate Fluid Capacities [1][2]Maintenance , Fluid and Lubricant Recommendations Maintenance , and Maintenance Schedule (North American Emissions) Maintenance.

51. Fill the engine with coolant. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (Vac N Fill) Cooling System Draining and Filling (Vac N Fill).

52. Check the transaxle fluid level. Refer to Adhesives, Fluids, Lubricants, and Sealers Adhesives, Fluids, Lubricants, and Sealers , Transmission General Specifications Transmission General Specifications , and Approximate Fluid Capacities [1][2]Maintenance.

53. Charge the AC system. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging.

54. Add power steering fluid and bleed air from the power steering system. Refer to Power Steering System Bleeding Service and Repair.

55. Prime the fuel system.

1. Cycle the ignition ON for 5 seconds then OFF for 10 seconds. Repeat cycling twice.

2. Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds.

3. If the engine does not start, repeat the steps.