Engine Replacement

Removal Procedure

^ Tools Required
- J 28467-A Universal Support Fixture
- J 28467-89 Engine Support Fixture Adapters (Metro)
- J 36295 Engine and/or Transmission Frame Handler

Important: The engine and the transaxle assembly is removed from the underside of the vehicle.

1. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure in Powertrain Management.

Caution: Refer to Battery Disconnect Caution in Service Precautions.

2. Remove the negative and the positive battery cables from the battery.
3. Remove the hood assembly. Refer to Hood Replacement in Body and Frame.
4. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
5. Remove the radiator with the cooling fan. Refer to Radiator Replacement in Cooling System.
6. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Powertrain Management.
7. Discharge the Air Conditioning (A/C) system. Refer to Refrigerant Recovery and Recharging in Heating and Air Conditioning.

Important: All of the components below are in one wiring harness.

8. Disconnect the following electrical connections:
^ The connector for the coolant temperature gauge sensor
^ The throttle position sensor connector
^ The purge solenoid valve connector
^ The Camshaft Position (CMP) sensor connector
^ The ground wire for the camshaft position (CMP) sensor
^ The Crankshaft Position (CKP) sensor connector
^ The solenoid valve connector for the Idle Speed Control (ISC)
^ The oxygen sensor connector (HO2S1)
^ The oxygen sensor connector (HO2S2)
^ The four fuel injector connectors
^ The connector for the Manifold Absolute Pressure (MAP) sensor
^ The switch for the Power Steering (P/S) pump pressure, if equipped
^ The oil pressure switch connector
^ The A/C compressor clutch connector
^ The Park/Neutral Position (PNP) switch connector
^ The ground wire connector from the intake manifold
^ The ignition coil connectors
^ The generator connector
^ The generator B+ wire
^ The starter solenoid connector
^ The positive battery cable from the starter solenoid
^ The backup lamp switch, if there is a manual transaxle
^ The vehicle speed sensor connector
^ Position the negative battery cable on top of the transaxle
^ The direct clutch and the second brake solenoid connector
9. Release the harness from the clamps, and position the harness aside.
10. Remove the lower canister purge hose from the purge solenoid valve, and position the hose aside.
11. Remove the brake booster hose from the intake manifold.
12. Remove the following cables:
^ The accelerator cable from the throttle body and the intake manifold
^ The clutch cable from the transaxle, for a manual transaxle
^ The shift select cable from the transaxle, for an automatic transaxle
^ The TV cable from the transaxle, for an automatic transaxle
^ The speedometer cable from the transaxle
13. Remove the inlet and the outlet hoses from the heater core.
14. Remove the fuel feed and the return hoses at the fuel rail.
15. Install the J 28467-A with the J 28467-89. Refer to Engine Support Fixture.
16. Remove the right side engine mount. Refer to Engine Mount Replacement (Right Engine Mount).
17. Remove the left transaxle mount. Refer to Transaxle Mount Replacement (Left) in Transmission and Drivetrain.
18. Remove the rear engine mount. Refer to Transmission and Drivetrain.
19. Raise and support the vehicle. Refer to Vehicle Lifting.
20. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement.
21. Drain the transaxle fluid. Refer to:
^ Fluid Replacement in Transmission and Drivetrain.
^ Automatic Transmission Fluid/Filter Changing in Transmission and Drivetrain.
22. Remove the two nuts and the front pipe and the catalytic converter assembly from the resonator and the center pipe.
23. Remove the two bolts and the front pipe and the catalytic converter assembly from the exhaust manifold.
24. Remove the hanger that is supporting the catalytic converter
25. Remove the front pipe and the catalytic converter assembly from the vehicle.
26. Remove the following components from the transaxle, for a manual transaxle:
^ The gearshift control shaft. Refer to Gearshift and Select Shaft Assembly Replacement in Transmission and Drivetrain.
^ The extension rod. Refer to Gearshift Control Shaft and Extension Rod Replacement in Transmission and Drivetrain.
27. Remove the torque rod, for an automatic transaxle. Refer to Engine Mount Replacement (Torque Rod Automatic Trans).

Important: For engine and for transaxle removal, it is not necessary to remove the wheel drive shaft from the steering knuckle.

28. Remove the left wheel drive shaft and the right wheel drive shafts from the transaxle. Refer to Wheel Drive Shafts Replacement in Transmission and Drivetrain.
29. Remove the A/C compressor. Refer to Compressor Replacement in Heating and Air Conditioning.
30. Remove the power steering pump, if equipped with power steering. Refer to Power Steering Pump Replacement in Steering and Suspension.
31. Lower the vehicle carefully until the vehicle rests on J 36295 the.
32. Remove the J 28467-A and the J 28467-89. Refer to Engine Support Fixture.

Important: Ensure sufficient clearance on all sides for removal of the engine and the transaxle assembly.

33. Raise the vehicle, leaving the engine and the transaxle assembly on the table.
34. Separate the engine from the transaxle.

Installation Procedure

^ Tools Required
- J 28467-A Universal Support Fixture
- J 28467-89 Engine Support Fixture Adapters (Metro)
- J 36295 Engine/Transmission Frame Handler

1. Install the engine to the transaxle.

Important: Ensure sufficient clearance on all sides for fitting the engine and the transaxle assembly into the engine compartment.

2. Lower the vehicle onto the engine and the transaxle assembly.
3. Install the J 28467-A and the J 28467-8. Refer to Engine Support Fixture.
4. Install the left transaxle mount. Refer to Transaxle Mount Replacement (Left) in Transmission and Drivetrain.
5. Install the right side engine mount. Refer to Engine Mount Replacement (Right Engine Mount).
6. Install the rear engine mount. Refer to:
^ Engine Mount Replacement (Rear Engine Mount-Automatic) in Transmission and Drivetrain.
^ Engine Mount Replacement (Rear Engine Mount-Manual) in Transmission and Drivetrain.
7. Raise the vehicle. Refer to Vehicle Lifting.
8. Install the power steering pump, if equipped with power steering. Refer to Power Steering Pump Replacement in Steering and Suspension.
9. Install the Air conditioning (A/C) compressor to the compressor bracket. Refer to Compressor Replacement in Heating and Air Conditioning.
10. Install the left drive axle and the right drive axle to the transaxle. Refer to Wheel Drive Shafts Replacement in Transmission and Drivetrain.
11. Install the torque rod. Refer to Engine Mount Replacement (Torque Rod Automatic Trans).
12. Install the Gearshift control shaft and the extension rod to the transaxle, if there is a manual transaxle. Refer to the following:
^ The Gearshift control shaft. Refer to Gearshift and Select Shaft Assembly Replacement in Transmission and Drivetrain.
^ The extension rod. Refer to Gearshift Control Shaft and Extension Rod Replacement in Transmission and Drivetrain.
13. Install the front pipe and the catalytic converter assembly to the vehicle. Support the catalytic converter with the hanger.
14. Install the front pipe and the catalytic converter assembly to the resonator and the center pipe. Secure the assembly with two nuts. Do not completely tighten.

Notice: Refer to Fastener Notice in Service Precautions.

15. Install the front pipe and the catalytic converter assembly to the exhaust manifold, and secure the assembly with 2 bolts.
^ Tighten the bolts for the exhaust manifold-to-front pipe catalytic converter to 50 Nm (37 ft. lbs.).
^ Tighten the resonator assembly nuts to 35 Nm (26 ft. lbs.).
16. Lower the vehicle.
17. Remove the J 28467-A and the J 28467-89 Refer to Engine Support Fixture.
13. Install the fuel feed and the return hoses to the fuel rail.
19. Install the heater inlet and the heater outlet hoses to the heater core.
20. Install the following cables:
^ The accelerator cable to the throttle body and the intake manifold
^ The clutch cable to the transaxle, for a manual transaxle
^ The shift select cable to the transaxle, for an automatic transaxle
^ The TV cable to the transaxle, for an automatic transaxle
^ The speedometer cable to the transaxle
21. Install the lower canister purge hose to the purge solenoid valve.
22. Install the brake booster hose to the intake manifold.
23. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging in Heating and Air Conditioning.
24. Route the harness, and secure the harness in the clamps.

Important: All of the components below are in one wiring harness

25. Connect the following electrical connections:
^ The connector for the coolant temperature gauge sensor
^ The throttle position sensor connector
^ The purge solenoid valve connector
^ The camshaft position (CMP) sensor connector
^ The ground wire for the camshaft position (CMP) sensor
^ The crankshaft position (CKP) sensor connector
^ The solenoid valve connector for the Idle Speed Control (ISC)
^ The oxygen sensor connector (HO2S1)
^ The oxygen sensor connector (HO2S2)
^ The four fuel injector connectors
^ The connector for the Manifold Absolute Pressure (MAP) sensor
^ The pressure switch for the power steering (P/S) pump, if equipped with power steering
^ The oil pressure switch connector
^ The A/C compressor clutch connector
^ The park/neutral position (PNP) switch connector
^ The ground wire connector from the intake manifold
^ The ignition coil connectors
^ The generator connector
^ The generator B+ wire
^ The starter solenoid connector
^ The positive battery cable to the starter solenoid
^ The backup lamp switch, for a manual transaxle
^ The vehicle speed sensor connector
^ Route the negative battery cable.
^ The direct clutch and the second brake solenoid connector
26. Install the radiator with the cooling fan. Refer to Radiator Replacement in Cooling System.
27. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
28. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Powertrain Management.
29. Fill the transaxle as necessary. Refer to:
^ Fluid Replacement in Transmission and Drivetrain.
^ Automatic Transmission Fluid/Filter Changing in Transmission and Drivetrain.
30. Fill the engine with engine oil. Refer to Engine Oil and Oil Filter Replacement.
31. Adjust the clutch pedal free travel, for a manual transaxle. Refer to Clutch Pedal Free Travel Adjustment in Transmission and Drivetrain.
32. Adjust the shift select cable, for an automatic transaxle. Refer to Shift Select Cable Replacement in Transmission and Drivetrain.
33. Adjust the TV cable, for an automatic transaxle. Refer to TV Cable Adjustment in Transmission and Drivetrain.
34. Adjust the accelerator cable free play. Refer to Accelerator Cable Adjustment in Powertrain Management.
35. Install the hood assembly. Refer to Hood Replacement in Body and Frame.
36. Install the positive battery cable and the negative battery cable to the battery.
37. Inspect the vehicle for the following conditions:
^ Fuel leaks
^ Water leaks
^ Exhaust gas leaks
38. Run the engine, and inspect the engine oil pressure.