Engine Replacement - Manual Transmission

Engine Replacement (Manual Transmission)

Removal Procedure

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure.
3. Drain cooling system.





4. Remove the alternative fuel module assembly. Remove the air cleaner outlet duct (1) and resonator assembly.





5. Remove the upper and lower radiator hoses from engine.
6. Disconnect the brake booster vacuum hose.
7. Disconnect the IAC electrical connection.
8. Disconnect the generator electrical connections.





9. Disconnect the Throttle Position (TPS) sensor electrical sensor.





10. Disconnect the MAP electrical connection.
11. Disconnect the EVAP emission solenoid electrical connection.
12. Disconnect the injector harness electrical connections.





13. Remove the following cables from the accelerator control bracket:
^ The accelerator control (2).
^ The cruise control (1).





14. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connection.





15. Disconnect the Oxygen (02S) sensor electrical connection.
16. Disconnect ignition control module connectors.





17. Disconnect the engine grounds electrical connection.





18. Remove the drive belt.
19. Disconnect the transmission shift control cable from the lever and bracket.
20. Disconnect hydraulic clutch line.





21. Remove the coolant surge tank.
22. Disconnect the vacuum line near the master cylinder.
23. Raise the vehicle. Refer to Vehicle Lifting.
24. Remove suspension support frame.





25. Disconnect the A/C compressor electrical connector.
26. Remove the A/C compressor and support with the lines attached.
27. Disconnect the vehicle speed sensor electrical connection.
28. Remove starter.
29. Disconnect the oil pressure sensor electrical connector.
30. Disconnect the ground wires.





31. Remove both of the drive axles from the transmission and Position them aside.
32. Lower vehicle until engine/transmission assembly is on support table.
33. Disconnect the heater hoses at the front of the dash.
34. Disconnect the fuel lines.
35. Remove the transmission mount through bolts.
36. Remove the engine mount assembly.
37. Raise the vehicle.
38. separate engine from the transmission.

Installation Procedure

1. Install the engine to the transmission.

Notice: Refer to Fastener Notice in Service Precautions.

2. Install the transmission bolts.
Tighten the bolts to 75 Nm (55 ft. lbs.).
3. Lower the vehicle onto the engine and transmission assembly.
4. Install the engine mount assembly.
5. Install the transmission mount through bolts.
6. Raise vehicle off support table.
7. Install both of the drive axles.
8. Install the suspension support frame.





9. Install starter.
10. Connect the oil pressure sensor electrical connection.
11. Connect the oil level sensor electrical connection.
12. Connect the grounds electrical connection
13. Install the A/C compressor.
14. Lower the vehicle.
15. Connect the lower radiator hose to the coolant pump.
16. Connect the heater hoses.





17. Install the following cables to the accelerator control bracket:
^ The accelerator control (2)
^ The cruise control (1)





18. Install the electronic ignition module electrical connection.
19. Connect the vacuum line near the master cylinder.
20. Install the coolant surge tank.
21. Connect the transmission shift control cables.





22. Connect hydraulic clutch line.
23. Install the drive belt.





24. Install the IAC electrical connection.
25. Connect the generator electrical connection.





26. Connect the Throttle Position (TPS) sensor electrical connection.





27. Connect the MAP electrical connection.





28. Connect the EVAP emission solenoid electrical connector.
29. Connect the injector harness.





30. Connect the Engine Coolant Temperature (ECT) sensor electrical connector.





31. Reconnect the Oxygen (02S) sensor.





32. Connect the engine ground wires.
33. Connect the brake booster vacuum hose.
34. Install the upper radiator hose at the coolant outlet.
35. Install the air cleaner inlet duct and resonator assembly.
36. Install the alternative fuel module assembly.
37. Fill the coolant system.
38. Refill the engine with oil.
39. Connect the negative battery cable.
Tighten the bolt to 16 Nm (12 ft. lbs.).
40. Connect the fuel lines.
41. Start the engine and check for leaks.
42. Turn the engine OFF and recheck the fluid levels.