Engine Replacement - Manual Transmission

Engine Replacement (Manual Transmission)

^ Tools Required
- J 42451 Engine Lift Bracket

Removal Procedure
1. Remove the hood.
2. Disconnect the negative battery cable.





3. Remove the air inlet duct and resonator (2).





4. Disconnect the accelerator and cruise control cable.
5. Disconnect the hose from the brake booster.





6. Remove the power steering pump bolts and set the pump aside.
7. Disconnect the fuel lines.





8. Disconnect the transmission shift control cables.





9. Disconnect the transmission shift control cables from the bracket.
10. Disconnect the clutch actuator cylinder from the transmission.

11. Drain the cooling system.





12. Remove the radiator inlet hose (3).
13. Remove the hose from the surge tank to the cylinder head (2).
14. Disconnect the outlet hose from the surge tank to the radiator (1).
15. Remove the bolt retaining the surge tank outlet hose to the intake manifold.





16. Remove the radiator outlet hose (1).





17. Remove the inlet (1) and outlet (2) heater hoses.
18. Disconnect the following electrical connectors:
^ IAC motor
^ TPS
^ Map sensor
^ Crankshaft sensor
^ Camshaft sensor
^ Oil pressure sensor
^ Purge solenoid
^ Ignition coil and module assembly
^ 02 sensor
^ Vehicle speed sensor
^ Engine temperature sensor
^ Back-up lamp switch





19. Unclip the electrical harness from the engine and set the harness aside.
20. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
21. Remove the front suspension crossmember.
22. Remove the drive axles.
23. Remove the engine drive belt.
24. Remove the AC compressor bolts and set the compressor aside.
25. Disconnect the generator electrical connectors.
26. Disconnect the starter electrical connectors.
27. Drain the engine oil.
28. Disconnect the front exhaust pipe from the exhaust manifold.
29. Use a block of wood to support the front of the engine at the front of the oil pan.
30. Lower the vehicle onto an engine support table.
31. Remove the front engine mount.
32. Remove the bolts, which secure the transmission mounts to the frame.
33. Raise the vehicle away from the engine and transmission assembly.
34. Install J 42451 or equivalent to the right rear of the cylinder head.
35. Install an engine hoist to the engine.
36. Remove the transmission bellhousing bolts.
37. Separate the engine and the transmission.
38. Remove the clutch pressure plate and disk.
39. Remove the engine flywheel.
40. Mount the engine to an engine stand.
41. Remove the following components:
^ Oil filter cap and filter.
^ Exhaust manifold studs
^ Exhaust manifold
^ Intake manifold studs
^ Intake manifold
^ Engine mount bracket
^ Engine lift bracket
^ Camshaft cover and seal
^ Fuel rail
^ Engine block heater
^ Water pump
^ Drive belt tensioner
^ Thermostat housing and feed pipe
^ Generator
^ Oil level indicator and tube
^ Crankshaft sensor
^ Camshaft sensor
^ Oil pressure sensor
^ Ignition coil and module assembly
^ Crankshaft balancer
42. Remove the engine from the stand.
43. Remove J 42451 or equivalent to the right rear of the cylinder head.

Installation Procedure





1. Install J 42451 or equivalent to the right rear of the cylinder head.
2. Mount the engine to a stand.
3. Install the following components:
^ Oil filter cap and filter.
^ Exhaust manifold studs
^ Exhaust manifold
^ Intake manifold studs
^ Intake manifold
^ Engine mount bracket
^ Engine lift bracket
^ Camshaft cover and seal
^ Fuel rail
^ Engine block heater
^ Water pump
^ Drive belt tensioner
^ Thermostat housing and feed pipe
^ Generator
^ Oil level indicator and tube
^ Crankshaft sensor
^ Camshaft sensor
^ Oil pressure sensor
^ Ignition coil and module assembly
^ Crankshaft balancer
4. Install an engine hoist to the engine.
5. Remove the engine from the engine stand.
6. Install the flywheel.
7. Install the clutch pressure plate and disk.
8. Install the engine to the transmission.
9. Install the engine and transmission assembly to an engine support table. Use a block of wood under the front of the engine to support the engine.
10. Remove the engine hoist.
11. Remove J 42451 or equivalent to the right rear of the cylinder head.
12. Position the engine support table under the vehicle.
13. Lower the vehicle while aligning the engine and transmission mounts to the vehicle.
14. Install the bolts, which secure the transmission mount to the frame.
15. Install the front engine mount.
16. Raise the vehicle.
17. Connect the front exhaust pipe to the exhaust manifold.
18. Connect the generator electrical connectors.
19. Connect the starter electrical connectors.
20. Install the AC compressor to the engine.
21. Install the engine drive belt.
22. Install the drive axles.
23. Install the front suspension cross member.
24. Lower the vehicle.
25. Connect the following electrical connectors:
^ IAC motor
^ TPS
^ Map sensor
^ Crankshaft sensor
^ Camshaft sensor
^ Oil pressure sensor
^ Purge solenoid
^ Ignition coil and module assembly
^ 02 sensor
^ Vehicle speed sensor
^ Engine temperature sensor
26. Install the radiator inlet hose (3).
27. Install the hose from the surge tank to the cylinder head (2).
28. Connect the outlet hose from the surge tank to the radiator (1).
29. Install the bolt retaining the surge tank outlet hose to the intake manifold.





30. Install the radiator outlet hose (1).





31. Install the inlet (1) and outlet (2) heater hoses.





32. Connect the transmission shift control cables to the bracket.





33. Connect the transmission shift control cables.
34. Connect the clutch actuator cylinder to the transmission.





35. Install the power steering pump and bolts.





36. Connect the accelerator and cruise control cable.
37. Connect the brake booster hose at the brake booster.
38. Connect fuel lines.





39. Install the air inlet duct and resonator (2).
40. Fill the engine with oil.
41. Connect the negative battery cable.
42. Fill the cooling system.
43. Install the hood.