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.

1. Disconnect the negative battery cable.
2. From inside the vehicle, disconnect the 2 engine control module (ECM) connectors.
3. Disconnect the 2 cowl wire electrical connectors from the connector mounting bracket.
4. Pull the engine harness wire from the passenger compartment.




5. Remove the 2 engine cover fasteners.
6. Remove the 2 engine cover plastic retainers.
7. Remove the engine cover (1) from the engine.
8. Relieve the fuel pressure.
9. Drain the cooling system.
10. Drain the engine oil.
11. Remove the serpentine drive belt.
12. If vehicle is equipped with A/C, remove the A/C compressor bolts and set A/C compressor aside.
13. If vehicle is equipped with a manual transmission, remove the following components:
^ The crankshaft pulley-Refer to Crankshaft Pulley Replacement.
^ The drive belt tensioner-Refer to Drive Belt Tensioner Replacement.




14. Remove the accelerator cable from the throttle body (1).
15. Remove the accelerator cable bracket from the throttle body.
16. Disconnect the intake air temperature (IAT) sensor.
17. Remove the air cleaner hose and cap assembly as follows:
^ Disconnect the mass air flow (MAF) sensor connector.
^ Disconnect 3 vacuum hoses from the air cleaner.
^ Disconnect the air intake hoses from the throttle body.
^ Unclip and remove the air cleaner cap.
18. Remove the air filter.
19. Disconnect the wire harness retaining clip from the air cleaner lower case.
20. Remove the following items from the air cleaner case:
^ The one bolt
^ The vacuum switching valve (VSV) bracket




21. Remove the following items:
^ The 3 bolts
^ The air cleaner lower box (3)
22. Disconnect the cruise control actuator electrical connector.
23. Remove the fuel line hose clamp.
24. Disconnect the fuel hose from the fuel line.
25. Disconnect the heater hose from the water by-pass pipe.
26. Disconnect the heater hose from the water hose union on the cylinder head.
27. Disconnect the brake booster vacuum hose from the brake booster.
28. Remove the radiator outlet hose.
29. Remove the radiator inlet hose.
30. Remove the generator.
31. Remove the radiator.
32. Remove the engine relay box cover.




33. Disconnect the 3 engine compartment relay box connectors (1, 2, 3).




34. Disconnect 2 ground cables (1, 2) from front left side of engine compartment.




35. Disconnect the 2 wire harness clamps.
36. If equipped with manual transaxle, disconnect the clutch actuator cylinder.




37. Disconnect the transaxle control cables from the transaxle.
1. Unclip the cable (1) from the mounting bracket.
2. Disconnect the transaxle control cables (2) from the transaxle.




38. If equipped with automatic transaxle, remove the shift cable from the transaxle.
1. Unclip the cable from the mounting bracket.
2. Remove the shift cable nut.




39. Unclip the wire harness (1), then remove the shift cable mounting bracket bolt (2).
40. Disconnect the oil cooler hoses.
41. On all models, remove the front drive axle.
42. Raise and properly support the vehicle.
43. Remove the right engine splash shield.
44. Remove left engine splash shield.




45. Place a drain pan, then disconnect the power steering lines (1) and drain the power steering system.
46. Remove the front exhaust pipe.
47. Disconnect the steering intermediate shaft assembly from under the dash panel.
48. Remove the right and left side driveshaft locknut.
49. Separate the left and right side tie rod end.
50. Disconnect the front stabilizer link assembly from the strut.
51. Remove 3 lower ball joint-to-control arm assembly nuts.




52. Set the engine lift, then remove the left side mounting insulator bolt and nut.




53. Remove the one bolt and 2 nuts from the right side engine mount.




54. Remove the 6 crossmember bolts.
55. 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.

3. Install the left side mounting insulator bolt and nut.

Tighten the left side mounting insulator nut and bolt 80 Nm (60 lb ft).




4. 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 lb ft).




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 lb ft).
^ Tighten the right and left side bolts (2) to 113 Nm (83 lb ft).




7. Install the crossmember rear bolts and tighten.

Tighten the crossmember rear bolts to 39 Nm (29 lb ft).

8. Connect the lower control arm assembly.

Tighten the nuts and the bolt to 89 Nm (65.6 lb ft).

9. Connect the front stabilizer link assembly.

Tighten the nut to 74 Nm (54.6 lb ft).

10. Install the left side tie rod end.

Tighten the outer tie rod nut to 49 Nm (36.1 lb ft). Align the cotter pin slot by tightening the outer tie rod nut up to 1/6 additional turn, or 70 Nm (52 lb ft) 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 lb ft).

12. Install the front exhaust pipe.




13. Connect the power steering lines (1), then refill the power steering system.
14. Connect the oil cooler hoses.
15. Install the right and left engine splash shield.
16. Lower the vehicle.
17. Install the steering intermediate shaft assembly.




18. Install the shift cable mounting bracket bolt (2) and clip the wire harness (1).

Tighten the bolt to 12 Nm (9 lb ft).




19. If equipped with an automatic transaxle, install the shift cable to the transaxle.
1. Install the shift cable nut.

Tighten the nut to 12 Nm (9 lb ft).

2. Clip the cable to the mounting bracket.
20. Pull the engine harness wire through the passenger compartment.
21. Connect the 3 cowl wire electrical connectors to the connector mounting bracket.
22. Connect the 2 ECM connectors.
23. Connect the ground cable to the engine.
24. Connect the ground cables to the transaxle.




25. If equipped with a manual transaxle, connect the transaxle control cables to the transaxle.
1. Connect the transaxle control cables (2) to the transaxle.
2. Clip the cable (1) to the mounting bracket.
26. Connect the clutch actuator cylinder.




27. Connect the 3 engine compartment relay box connectors (1, 2, 3).




28. Connect 2 ground cables (1, 2) from front left side of engine compartment.

Tighten the bolts to 9 Nm (7 lb ft).




29. Connect the 2 wire harness clamps.
30. Install the engine relay box cover.
31. Install the radiator.
32. Install the generator.
33. Install the radiator inlet hose.
34. Install the radiator outlet hose.
35. Connect the brake booster vacuum hose to the brake booster.
36. Connect the heater hose to the water hose union on the cylinder head.
37. Connect the heater hose to the water by-pass pipe.
38. Connect the fuel tube to the fuel pipe.
39. Install the fuel tube clamp.
40. Connect the cruise control actuator electrical connector.




41. Install the air cleaner case as follows:
1. Install the air cleaner, then the 3 air cleaner case bolts (2).

Tighten the bolts to 7 Nm (62 lb in).

2. Connect the air cleaner wire harness clamp, connector, and hose.
3. Install the air filter.
42. Install the air cleaner cover as follows:
1. Install the air cleaner cap and air cleaner hose assembly.
2. Connect the air cleaner hose to the throttle body, then tighten the air cleaner hose clamp bolt.
3. Connect the air cleaner cap to the air cleaner case, then latch the 2 air cleaner clamps.
4. Connect the MAF sensor connector.
43. Connect the IAT sensor.




44. Connect the accelerator cable to the throttle body (1).
45. Install the accelerator cable to the accelerator cable bracket.
46. If the vehicle is equipped with a manual transmission, remove the following components:
^ The drive belt tensioner-Refer to Drive Belt Tensioner Replacement.
^ The crankshaft pulley-Refer to Crankshaft Pulley Replacement.
47. If the vehicle is equipped with A/C, position the A/C compressor and install the A/C compressor bolts.
48. Install the serpentine drive belt.
49. Refill the engine oil.
50. Refill the cooling system.
51. Connect the negative battery cable.




52. Position the engine cover (1) to the engine.
53. Install the 2 engine cover plastic retainers.
54. Install the 2 engine cover fasteners.
55. Start the engine and check for fluid leaks.