Engine Replacement

Engine Replacement

^ Tools Required
- J 36854 Heavy Duty Automotive Engine Stand
- J 36660-A Torque Angle Meter

Removal Procedure

Caution: Refer to Battery Disconnect Caution in Service Precautions.

1. Disconnect the battery.
2. From inside the vehicle disconnect the 2 ECM connectors.
3. Disconnect the 3 cowl wire electrical connectors from the connector mounting bracket.
4. From the engine compartment, pull the engine harness wire from the passenger compartment.
5. Remove the steering shaft coupling.





6. Remove the engine cover (1).
7. Relieve the fuel pressure.
8. Drain the cooling system.
9. Disconnect the accelerator cable.
10. Remove the air cleaner cover.
11. Remove the air filter.
12. Remove the 3 air cleaner case bolts, then the air cleaner.
13. Remove the fuel tube clamp.
14. Disconnect the fuel tube from the fuel pipe.
15. Disconnect the heater hose from the water by-pass pipe.
16. Disconnect the heater hose from the water hose union on the cylinder head.
17. Disconnect the brake booster vacuum hose from the brake booster.
18. Disconnect the radiator inlet hose.
19. Disconnect the radiator outlet hose.
20. Remove the accessory drive belt.
21. Remove the generator.
22. Remove the radiator.
23. Remove 2 clutch slave cylinder bolts.
24. Remove 1 clutch slave cylinder line retaining bolt.
25. Remove 1 clutch slave cylinder line bracket retaining bolt.
26. Remove the engine relay box cover.





27. Disconnect the 3 engine compartment relay box connectors.





28. Disconnect the 2 wire harness clamps.
29. Disconnect the ground cables from the transaxle.
30. Disconnect the ground cable from the engine.
31. Disconnect the clutch actuator cylinder.





32. If equipped with manual transaxle, disconnect the transaxle control cables from the transaxle.
32.1. Unclip the cable (1) from the mounting bracket.
32.2. Disconnect the transaxle control cables (2) from the transaxle.





33. If equipped with automatic transaxle, remove the shift cable from the transaxle.
33.1. Unclip the cable from the mounting bracket.
33.2. Remove the shift cable nut.
34. Raise and properly support the vehicle. Refer to Vehicle Lifting.
35. Remove the left side engine splash shield.
36. Remove the right side engine splash shield.
37. Drain the engine oil.
38. If equipped with AWD, remove the propeller shaft.





39. Place a drain pan, then disconnect the power steering lines (1) and drain the power steering system.





40. Remove the front exhaust pipe.
41. Remove the right and left side driveshaft locknut.
42. Separate the left and right side tie rod end.
43. Disconnect the front stabilizer link assembly from the strut.
44. Remove three lower ball joint-to-control arm assembly nuts.
45. Set the engine lift, then remove the left side mounting insulator bolt and nut.





46. Remove the 5 bolts and 2 nuts from the right side engine mount.





47. Remove the 6 crossmember bolts.
48. Lower the engine and transaxle assembly.

Installation Procedure





1. Raise the engine and transaxle assembly.
2. Temporarily install the 6 crossmember bolts.





Notice: Refer to Fastener Notice in Service Precautions.

3. Install the 5 bolts and 2 nuts from the right side engine mount, then remove the engine lift.
^ Tighten the right side engine mount nuts and bolts to 52 Nm (38 ft. lbs.).





4. Install the left side mounting insulator bolt and nut.
^ Tighten the left side mounting insulator nut and bolt 80 Nm (60 ft. lbs.).





5. Align the right side of the crossmember, then install and temporarily tighten bolt (1), then bolt (2).





6. Align the left side of the crossmember, then install and temporarily tighten bolt (1), then bolt (2).
^ Tighten the right and left side bolts (1) to 157 Nm (116 ft. lbs.).
^ Tighten the right and left side bolts (2) to 113 Nm (83 ft. lbs.).





7. Install the crossmember rear bolts and tighten.
^ Tighten the crossmember rear bolts to 39 Nm (29 ft. lbs.).





8. Connect the lower control arm assembly.
^ Tighten the nuts and the bolt to 89 Nm (65.6 ft. lbs.).
9. Connect the front stabilizer link assembly.
^ Tighten the nut to 74 Nm (54.6 ft. lbs.).
10. Install the left side tie rod end.
^ Tighten the outer tie rod nut to 49 Nm (36.1 ft. lbs.). Align the cotter pin slot by tightening the outer tie rod nut up to 1/6 additional turn, or 70 Nm (52 ft. lbs.) maximum. Do not loosen the nut in order to insert the cotter pin.
11. Install the drive shaft lock nut.
^ Tighten the nut to 216 Nm (159 ft. lbs.).
12. Install the front exhaust pipe.
13. Connect the power steering lines (1), then refill the power steering system.





14. If equipped with AWD, install the propeller shaft.
15. Install the left side engine splash shield.
16. Install the right side engine splash shield.
17. Lower the vehicle.
18. Connect the 3 engine compartment relay box connectors.





19. Install the engine relay box cover.
20. Install 1 clutch slave cylinder line bracket retaining bolt.
21. Install 1 clutch slave cylinder line retaining bolt.
22. Install 2 clutch slave cylinder bolts.
23. If equipped with automatic transaxle, install the shift cable to the transaxle.
23.1. Install the shift cable nut.
23.2. Clip the cable to the mounting bracket.





24. If equipped with manual transaxle, connect the transaxle control cables to the transaxle.
24.1. Connect the transaxle control cables (2) to the transaxle.
24.2. Clip the cable (1) to the mounting bracket.





25. Connect the clutch actuator cylinder.
26. Connect the ground cable to the engine.
27. Connect the ground cables to the transaxle.
28. Connect the 2 wire harness clamps.





29. Install the radiator.
30. Install the generator.
31. Install the accessory drive belt.
32. Install the radiator inlet hose.
33. Install the radiator outlet hose.
34. Connect the brake booster vacuum hose to the brake booster.
35. Connect the heater hose to the water hose union on the cylinder head.
36. Connect the heater hose to the water by-pass pipe.
37. Connect the fuel tube to the fuel pipe
38. Install the fuel tube clamp.
39. Install the air cleaner case.
^ Tighten the bolts to 7 Nm (62 inch lbs.).
40. Install the air filter.
41. Install the air cleaner cover.
42. Connect the accelerator cable.
43. Refill the engine oil.
44. Refill the cooling system.
45. If the vehicle is equipped with A/C, position the A/C compressor and install the A/C compressor bolts.
46. Install the accessory drive belt.
47. Install the steering shaft coupling.
48. Pull the engine harness wire through the passenger compartment.
49. Connect the 3 cowl wire electrical connectors from the connector mounting bracket.
50. Connect the 2 ECM connectors.
51. Install the battery.
52. Install the engine cover (1).
53. Start the engine and check for fluid leaks.