Engine Replacement
Engine Replacement- Tools Required
- J39580 Universal Engine Support Table
Removal Procedure
1. Disconnect the battery ground (negative) cable.
2. Remove the throttle body air inlet duct.
3. Remove the cruise control cable from the engine and reposition the cable away from the engine.
Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.
In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.
4. Remove the accelerator control cable from the engine and reposition the cable away from the engine.
5. Drain the engine coolant from the cooling system
6. Disconnect the radiator hoses from the engine.
7. Disconnect the heater hoses from the engine.
8. Remove the engine mount struts.
Important: Relief the fuel pressure.
9. Disconnect the fuel lines from the fuel rail.
10. Remove the engine wiring harness connectors.
11. Remove the vacuum hoses from the engine.
12. Remove the vacuum brake booster hose.
13. Remove the automatic transaxle range selector cable.
14. Raise and support the vehicle. Refer to Vehicle Lifting.
15. Drain the engine oil.
16. Remove the A/C compressor bolts and position the A/C compressor aside.
17. Remove the wiring harness grounds.
18. Remove the three-way catalytic converter exhaust pipe from the engine right side exhaust manifold.
19. Remove the front tires and wheels.
20. Remove the engine splash shields.
21. Remove the stabilizer shaft links from the lower control arms.
22. Remove the tie rod ends from the steering knuckles.
23. Remove the lower ball joints from the knuckles.
24. Remove the transaxle cooler lines and bracket from the transaxle.
25. Disconnect the drive axles from the transaxle.
26. Secure the drive axles to the steering knuckle/struts.
Caution: Failure to disconnect the intermediate shaft from the rack and pinion steering gear stub shaft can result in damage to the steering gear and/or intermediate shaft. This damage may cause loss of steering control which could result in an accident and possible personal injury
27. Remove the intermediate shaft from the steering gear.
28. Lower the vehicle until the frame contacts the transaxle table J39580.
29. Remove the frame bolts.
30. Raise the vehicle in order to separate the powertrain/frame from the vehicle.
31. Remove the engine-to-transaxle bolts (3, 4, 5 and 6) and studs (1 and 2).
32. Remove the engine flywheel to torque converter bolts.
33. Remove the engine from the transaxle/frame to the engine stand.
Installation Procedure
1. Install the engine to the transaxle/frame from the engine stand.
Notice: Refer to Fastener Notice in Service Precautions.
2. Install the engine-to-transaxle bolts (3, 4, 5 and 6) and studs (1 and 2).
- Tighten the engine-to-transaxle bolts (3, 4, 5 and 6) and studs (1 and 2) to 75 Nm (55 ft. lbs.).
3. Install the engine flywheel to torque converter bolts.
4. Position the transaxle table with the powertrain/frame under the vehicle.
5. Lower the vehicle until the body contacts the frame.
6. Install the NEW frame bolts.
7. Raise and support the vehicle. Refer to Vehicle Lifting.
8. Remove the transaxle table.
Caution: When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation, the two mating shafts may disengage. Disengagement of the two mating shafts will cause loss of steering control which could result in personal injury.
9. Install the intermediate shaft to steering gear.
10. Install the drive axles to the transaxle.
11. Install the transaxle cooler lines and bracket to the transaxle.
12. Install the A/C compressor.
13. Install the engine oil filter.
14. Install the lower ball joints to the knuckles.
15. Install the tie rod ends to the steering knuckles.
16. Install the stabilizer shaft links to the lower control arms.
17. Install the inner fender splash shield.
18. Install the front tires and wheels.
19. Install the three-way catalytic converter exhaust pipe to the engine right side exhaust manifold.
20. Install the wiring harness grounds.
21. Lower the vehicle
22. Install the automatic transaxle range selector cable.
23. Install the vacuum brake booster hose.
24. Install the vacuum hoses to the engine.
25. Install the engine wiring harness connectors.
26. Install the fuel lines to the fuel rail.
27. Install the throttle body bracket and cables.
28. Install the engine mount strut.
29. Connect the heater hoses to the engine.
30. Connect the radiator hoses to the engine.
31. Fill the cooling system with engine coolant.
32. Adjust the transaxle fluid level.
33. Fill the engine with oil.
Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.
In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.
34. Install the accelerator control cable to the engine.
35. Install the cruise control cable to the engine.
36. Install the throttle body air inlet duct.
37. Connect the battery ground (negative) cable.
38. Perform the CKP system variation learn procedure.
39. Inspect for proper fluid levels and possible fluid leaks