Engine Replacement - Manual Transmission

Engine Replacement (Manual Transmission)

Removal Procedure





1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure.
3. Drain the cooling system.
4. 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 (O2S) 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 from the 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 the suspension support frame.
25. Disconnect the A/C compressor electrical connector.
26. Remove the A/C compressor and support the compressor with the lines attached.
27. Disconnect the electrical connection from the vehicle speed sensor.
28. Remove the starter.
29. Disconnect the electrical connector from the oil pressure sensor.





30. Disconnect the ground wires.
31. Remove both of the drive axles from the transmission and position the axles aside.
32. Lower the vehicle until the engine/transmission assembly is on the 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 the 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 the vehicle from the support table.
7. Install both drive axles.





8. Install the suspension support frame.
9. Install the starter.





10. Connect the electrical connection to the oil pressure sensor.
11. Connect the electrical connection to the oil level sensor.
12. Connect the electrical connection to ground.
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. Connect the electrical connection to the electronic ignition module.
19. Connect the vacuum line near the master cylinder.
20. Install the coolant surge tank.
21. Connect the transmission shift control cables.





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





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





26. Connect the electrical connection to the TPS.





27. Connect the MAP electrical connection.





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





30. Connect the electrical connector to the ECT sensor.





31. Reconnect the O2S 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. Fill the coolant system.
37. Refill the engine with oil.
38. Connect the negative battery cable using the battery cable bolt.
^ Tighten the bolt to 16 Nm (12 ft. lbs.).
39. Connect the fuel lines.
40. Start the engine and inspect for leaks.
41. Turn the engine OFF and reinspect the fluid levels.