Engine Removal and Installation

REMOVAL PROCEDURE





1. Disconnect the battery ground (negative) cable.
2. Remove the fuel injector sight shield. Refer to Engine Cover Replacement Service and Repair
3. Remove the throttle body air inlet duct.
4. Drain the engine coolant from the cooling system.
5. Disconnect the radiator hoses from the engine.
6. Disconnect the heater hoses from the engine.
7. Remove the engine mount struts.

IMPORTANT: Relieve the fuel pressure.

8. Disconnect the fuel hoses from the fuel rail.
9. Remove the engine wiring harness connectors.
10. Remove the vacuum brake booster hose.
11. Remove the vacuum hoses from the engine.
12. Remove the automatic transaxle range selector cable.
13. Raise and suitably support the vehicle.
14. Drain the engine oil.
15. Remove the wiring harness grounds.
16. Remove the three-way catalytic converter exhaust pipe from the right (rear) exhaust manifold.
17. Remove the front tires and wheels.
18. Remove the engine splash shields.
19. Remove the stabilizer shaft links from the lower control arms.
20. Remove the tie rod ends from the steering knuckles.
21. Remove the lower ball joints from the knuckles.
22. Remove the transaxle cooler lines and bracket from the transaxle.
23. Disconnect the drive axles from the transaxle.
24. 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 NOSY CAUSE LOSS OF STEERING CONTROL WHICH COULD RESULT IN AN ACCIDENT AND POSSIBLE PERSONAL INJURY.

25. Remove the pinch bolt/screw at the intermediate steering shaft.
26. Disconnect the intermediate shaft from the steering gear.
27. Support the engine/transaxle/frame with the transaxle table.
28. Remove the frame-to-body bolts/screws.
29. Lower the frame with the engine/transaxle from the vehicle.





30. Remove the engine-to-transaxle bolts (3, 4, 5 and 6) and studs (1 and 2).
31. Remove the engine flywheel to torque converter bolts.
32. 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.





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. Raise and install the frame with the engine/transaxle to the vehicle.
5. Install the frame-to-body bolts/screws.
6. 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.

7. Connect the intermediate shaft to steering gear.
8. Connect the drive axles to the transaxle.
9. Install the transaxle cooler lines and bracket to the transaxle.
10. Install the lower ball joints to the knuckles.
11. Install the tie rod ends to the steering knuckles.
12. Install the stabilizer shaft links to the lower control arms.
13. Install the engine splash shields.
14. Install the front tires and wheels.
15. Install the three-way catalytic converter exhaust pipe to the right (rear) exhaust manifold.
16. Install the wiring harness grounds.
17. Lower the vehicle
18. Install the automatic transaxle range selector cable.
19. Install the vacuum brake booster hose.
20. Install the vacuum hoses to the engine.
21. Install the engine wiring harness connectors.
22. Connect the fuel hoses to the fuel rail.
23. Install the accelerator cable bracket to the throttle body.

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.

24. Install a NEW accelerator control cable.
25. Install the engine mount strut.
26. Connect the heater hoses to the engine.
27. Connect the radiator hoses to the engine.
28. Fill the cooling system with engine coolant.
29. Adjust the transaxle fluid level.
30. Fill the engine with oil.





31. Install the throttle body air inlet duct.
32. Install the fuel injector sight shield. Refer to Engine Cover Replacement Service and Repair
33. Connect the battery ground (negative) cable.
34. Perform the CKP system variation learn procedure.
35. Inspect for proper fluid levels and possible fluid leaks.