Engine Replacement

Engine Replacement

Removal Procedure

1. Disconnect the negative battery cable.
2. Remove the intake manifold cover.
3. 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).
4. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement.
5. Remove the air cleaner assembly.
6. Remove the hood.
7. Remove the engine mount strut.
8. Remove the drive belt.




9. Disconnect the front knock sensor (KS).




10. Disconnect the rear knock sensor (KS)




11. Disconnect the camshaft position (CMP) sensor, crankshaft position (CKP) sensor and the oil control valves.




12. Disconnect the manifold absolute pressure (MAP) sensor




13. Disconnect the evaporative emission (EVAP) canister purge solenoid




14. Disconnect the front and rear ignition coils




15. Disconnect the A/C Compressor




16. Disconnect the coolant temperature sensor
17. Disconnect the following electrical connectors:

* The heated oxygen sensor (HO2S)
* The exhaust gas recirculation (EGR) valve
* The electronic throttle control
* The body wiring harness-to-engine harness

18. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
19. Remove the catalytic converters.




20. Remove the engine wiring harness grounds from the transaxle.




21. Remove the engine mount lower bolts.
22. Remove the torque converter covers.
23. Remove the starter motor.
24. Remove the air conditioning (A/C) compressor. DO NOT discharge the A/C system. Support the compressor.
25. Remove the torque converter bolts.
26. Remove the engine mount bracket.




27. Remove the transaxle to oil pan brace bolts and brace.




28. Remove the lower transaxle-to-engine bolt (6) and the stud (1).
29. Remove the radiator outlet hose from the engine.
30. Lower the vehicle and support the transaxle.
31. Remove the heater outlet and inlet hoses from the engine.
32. Remove the vacuum hoses from the upper intake manifold.
33. Remove the brake booster vacuum hose from the upper intake manifold.
34. Remove the fuel lines from the fuel rail.
35. Remove the radiator inlet hose from the engine.
36. Install the engine lifting device to the engine.
37. Remove the upper transaxle-to-engine bolts (3, 4, 5) and the stud (2).
38. Remove the engine from the vehicle.
39. Remove the flywheel.
40. Install the engine to the engine stand.

Installation Procedure




1. Remove the engine from the engine stand.
2. Install the flywheel.
3. Install the engine to the vehicle.

Notice: Refer to Fastener Notice.

4. Install the upper transaxle-to-engine bolts (3, 4, 5) and the stud (2).

Tighten the bolts (3, 4, 5) and the stud (2) to 75 Nm (55 lb ft).

5. Remove the engine lifting device.
6. Install the radiator inlet hose to the engine.
7. Install the fuel lines to the fuel rail.
8. Install the brake booster vacuum hose to the upper intake manifold.
9. Install the vacuum hoses to the upper intake manifold.
10. Install the heater inlet and outlet hoses to the engine.
11. Raise the vehicle and remove the transaxle support.
12. Install the radiator outlet hose to the engine.
13. Install the lower transaxle-to-engine bolt (6) and the stud (1).

Tighten the bolt (6) and the stud (1) to 75 Nm (55 lb ft).




14. Position the transaxle to oil pan brace and install the bolts.

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

15. Install the engine mount bracket.
16. Install the torque converter bolts.
17. Install the A/C compressor.
18. Install the starter motor.
19. Install the torque converter covers.




20. Install the engine mount lower bolts.

Tighten the bolts to 50 Nm (38 lb ft).




21. Install the engine wiring harness grounds to the transaxle.
22. Install the engine wiring harness ground nut to the transaxle stud.

Tighten the nut to 35 Nm (26 lb ft).

23. Install the catalytic converters.
24. Lower the vehicle.
25. Connect the following electrical connectors:

* The body wiring harness-to-engine harness
* The electronic throttle control
* The exhaust gas recirculation (EGR) valve
* The heated oxygen sensor (HO2S)




26. Connect the coolant temperature sensor




27. Connect the A/C Compressor




28. Connect the front and rear ignition coils




29. Connect the evaporative emission (EVAP) canister purge solenoid




30. Connect the manifold absolute pressure (MAP) sensor




31. Connect the camshaft position (CMP) sensor, crankshaft position (CKP) sensor and the oil control valves.




32. Connect the rear knock sensor (KS)




33. Connect the front knock sensor (KS).
34. Install the drive belt.
35. Install the engine mount strut.
36. Install the hood.
37. Install the air cleaner assembly.
38. Connect the negative battery cable.
39. Fill the crankcase with engine oil. Refer to Engine Oil and Oil Filter Replacement.
40. Fill 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).
41. Perform a CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn. Service and Repair
42. Install the intake manifold cover.
43. Inspect for leaks.