Engine Replacement

Engine Replacement

Removal Procedure

1. With the tires in the straight forward position, remove the key from the ignition.
2. Disconnect the negative battery cable.
3. Remove the air inlet duct and resonator.




4. Secure the cooling module to the upper body structure.
5. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027).
6. Disconnect the fuel line from the fuel rail.
7. Drain the cooling system. Refer to Draining and Filling Cooling System (LY7, LZ4, LZ9 Static Fill) Draining and Filling Cooling System (GE 47716 Fill) Draining and Filling Cooling System (LE5 Static Fill).
8. Remove the radiator inlet hose.
9. Remove the surge tank to cylinder head hose.
10. Remove the radiator outlet hose.




11. Remove the inlet (1) and outlet (2) heater hoses.
12. Disconnect the following harness connectors:

* The electronic throttle control
* The manifold absolute pressure (MAP) sensor
* The crankshaft sensor
* The oil pressure sensor
* The purge solenoid
* The ignition coils
* The heated oxygen sensor (HO2S) sensor
* The vehicle speed sensor (VSS)
* The engine temperature sensor
* The back-up lamp switch
* The camshaft position actuator solenoid control valves
* The fuel rail.

13. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.
14. Remove the engine drive belt.
15. Remove the AC compressor bolts and set the compressor aside.




16. Remove the starter solenoid battery cable nut (2).
17. Remove the positive battery cable lead (3) from the starter solenoid.




18. Remove the starter solenoid engine harness nut (1).
19. Remove the engine harness lead (2) from the starter solenoid.




20. Disconnect the generator electrical connector (1).
21. Reposition the engine harness rubber boot (3).
22. Remove the generator nut (2).
23. Remove the engine harness lead (4) from the generator.
24. Disconnect the front exhaust pipe from the exhaust manifold.
25. Lower the vehicle.
26. Disconnect the transmission harness connectors.
27. Disconnect the transmission shift cable from the transmission.
28. Use blocks of wood to support the powertrain assembly between the frame and the powertrain.
29. Remove the engine mount.




30. Remove the side transmission mount bracket bolts.
31. Raise the vehicle.




32. Disconnect the stabilizer links from the stabilizer bar.




33. Disconnect the outer tie rod ends from the steering knuckles.





Important: In order to prevent possible supplemental inflatable restraint (SIR) system deployment, do not attempt to rotate the steering shaft.

34. Disconnect the intermediate shaft from the steering gear.




35. Disconnect the lower control arms from the steering knuckles.
36. Disconnect the drive axles from the transaxle and support with wire or bungee cords.
37. Use a paint pen or magic marker in order to mark the frame to body position.




38. Lower the vehicle to about 3 feet off the ground in order to position the lift table under the frame.
39. Use wood blocks as necessary between the lift table and the frame to support the assembly.
40. Remove the frame bolts using the following sequence:

1. Remove the front frame bolts.
2. Remove the rear frame bolts.

41. Slowly raise the vehicle off of the frame and powertrain.
42. Attach the engine lift hoist to the engine lift hooks.




43. Remove the starter bolts and starter.




44. Remove the transaxle brace to engine bolts.
45. Remove the transaxle brace to transaxle bolts and brace.
46. Remove the torque converter to flywheel bolts.
47. Remove the transaxle to engine bolts.
48. Separate the engine from the transaxle.
49. Remove the following components:

* The exhaust manifold
* The engine mount bracket
* The engine block heater
* The thermostat housing and feed pipe
* The generator
* The fuel rail
* The drive belt tensioner

50. Install the engine to a suitable engine stand.

Installation Procedure

1. Attach the engine lift hoist to the engine lift hooks.
2. Install the following components:

* The exhaust manifold-Refer to Exhaust Manifold Replacement (LE5).
* The engine mount bracket-Refer to Engine Mount Bracket Replacement.
* The fuel rail-Refer to Fuel Rail Assembly Replacement.
* The engine block heater, if equipped-Refer to Coolant Heater Replacement (LE5) Coolant Heater Replacement (LZ4 and LZ9).
* The drive belt tensioner-Refer to Drive Belt Tensioner Replacement.
* The thermostat housing and feed pipe-Refer to Thermostat Replacement (LE5) Thermostat Replacement (LZ4/LZ9).
* The generator-Refer to Generator Replacement (LE5) Generator Replacement (LZ4) Generator Replacement (LZ9) Generator Replacement (LY7).
* The flywheel-Refer to Engine Flywheel Replacement.

3. Align the engine to the transaxle.





Notice: Refer to Fastener Notice.

Important: The number 3 bolt location is not used.

4. Install the engine to the transaxle bolts.

Tighten the bolts to 75 Nm (55 lb ft).

5. Install the torque converter bolts.

Tighten the bolts to 62 Nm (46 lb ft).




6. Position the transaxle brace to the engine and transaxle and install the brace to transaxle bolts.
7. Install the transaxle brace to engine block bolts.

Tighten the bolts to 50 Nm (37 lb ft).




8. Install the starter.
9. Remove the engine lift from the engine.




10. Lower vehicle slowly over frame and powertrain.
11. Hand start all the frame bolts while aligning the frame to the paint marks.
12. Tighten the frame bolts.

Tighten the frame bolts to 100 Nm (74 lb ft) plus an additional 180 degrees.

13. Remove the lift table.
14. Connect the drive axles to the transaxle.




15. Connect the lower control arm to the steering knuckle.




16. Connect the intermediate steering shaft to the steering gear.




17. Connect the outer tie rod ends to the steering knuckles.




18. Connect the stabilizer links to the stabilizer bar.




19. Install the side transmission mount bracket bolts.

Tighten the bolts to 50 Nm (37 lb ft).

20. Install the engine mount.
21. Remove the wood blocks between the powertrain and frame.
22. Connect the transmission shift cable to the transmission.
23. Connect the transmission harness connector.




24. Install the catalytic converter to the exhaust manifold.

Tighten the nuts to 30 Nm (22 lb ft).

25. Lower the vehicle.




26. Install the engine harness lead (4) to the generator.
27. Install the generator nut (2).

Tighten the nut to 20 Nm (15 lb ft).

28. Position the engine harness rubber boot (3).
29. Connect the generator electrical connector (1).
30. Raise the vehicle.




31. Install the engine harness lead (2) to the starter solenoid.
32. Install the starter solenoid engine harness nut (1).

Tighten the nut to 3 Nm (27 lb in).




33. Install the positive battery cable lead (3) to the starter solenoid.
34. Install the starter solenoid battery cable nut (2).

Tighten the nut to 17 Nm (13 lb ft).

35. Install the AC compressor to the engine.
36. Install the engine drive belt.
37. Connect the following harness connectors:

* The electronic throttle control
* The MAP sensor
* The crankshaft sensor
* The oil pressure sensor
* The purge solenoid
* The ignition coils
* The HO2S
* The VSS
* The engine temperature sensor
* The camshaft position actuator solenoid control valves
* The fuel rail




38. Install the inlet heater hose (1) and outlet heater hose (2).
39. Install the radiator outlet hose.
40. Connect the fuel line to the fuel rail.




41. Release the cooling module from the upper body structure.
42. Install the air inlet duct and resonator.
43. Connect the negative battery cable.
44. Fill the engine with engine oil to the proper level. Refer to Fluid and Lubricant Recommendations.
45. Fill the cooling system. Refer to Draining and Filling Cooling System (LY7, LZ4, LZ9 Static Fill) Draining and Filling Cooling System (GE 47716 Fill) Draining and Filling Cooling System (LE5 Static Fill).
46. Road test the vehicle.