Engine Replacement

Engine Replacement (FWD)

Special Tools

- CH-49289 Blue Tool
- CH-49290 Orange Tool

Removal Procedure

1. Turn the ignition OFF.
2. Remove the intermediate steering shaft fastener.
3. Remove the engine sight shield.
4. Evacuate the air conditioning system.
5. Remove the engine control module.
6. Remove the battery tray.
7. Remove the air cleaner outlet duct.
8. Remove the air cleaner assembly.
9. Remove the charge air cooler air hose.
10. Remove the front bumper fascia.
11. Drain the cooling system.
12. Disconnect the engine wiring harness connectors (1, 2, 3).





13. Remove the engine wiring harness ground connectors (1) from the front end upper tie bar support.





14. Remove the engine wiring harness (1) from the front compartment fuse block housing (2).





15. Position and secure the wiring harness to the engine.
16. Remove the radiator surge tank hoses from the radiator surge tank.
17. Position and secure the surge tank hoses to the engine.
18. Remove the engine coolant air bleed hose.
19. Remove the manual transmission shift lever cable from the transmission.
20. Position and secure the manual transmission shift lever cable to the vehicle.
21. Remove the power brake booster pipe (1) from the power brake booster (2).





22. Remove the heater inlet hose and the heater outlet hose from the heater core.
23. Relieve the fuel system pressure.
24. Remove the fuel feed front pipe.
25. Disconnect the evaporative pipe quick connector (1).





26. Remove the air conditioning compressor and the condenser hose and the air conditioning evaporator hose.
27. Raise and support the vehicle.
28. Remove the front wheels.
29. Remove the both front wheel drive shaft fasteners.
30. Remove the stabilizer shaft link fasteners.
31. Remove the steering linkage outer tie rod fasteners.
32. Remove both steering knuckles from both front lower control arms.
33. Remove both front wheel drive shafts from both front wheel bearings and hubs.
34. Disconnect both front wheel speed sensor electrical connectors. Position and secure both wiring harnesses to the vehicle.
35. Disconnect the power steering wiring harness connector (2).





36. Disconnect the engine coolant fan motor wiring harness connectors (1).
37. Remove the relay box (1).





38. Position and secure the relay box to the engine.
39. Remove exhaust front pipe.
40. Remove both drivetrain and front suspension frame transmission protectors.
41. If available remove the engine shield from the front suspension frame.
42. Raise the vehicle enough to place a suitable lift table under the engine, transmission, front frame and front suspension assembly.
43. Position a suitable powertrain or engine lift table below the frame, engine and transmission.
44. Install the CH-49290 tool.
45. Remove the powertrain lift/support table.
46. Lower the vehicle.
47. Remove the engine mount bracket from the engine mount support.
48. Remove the transmission mount fasteners.
49. Raise the vehicle.
50. Install the CH-49289 tool.
51. Raise the lift table or lower the vehicle to support the frame, engine and transmission.

52. Note
Positioning pins (2, 3) of CH-49289 adapter MUST stick into holes of drivetrain frame.

Check if wheel alignment is required.





- Move out position pins (1) and try to insert into underbody holes.
- If guide pins can NOT be inserted, the Wheel Alignment Measurement is required after installation of drive train frame.
53. Remove the front suspension frame fasteners.

54. Note
Ensure that all the hoses, wires, pipes and shock modules clear the vehicle during the removal process.

With the aid of an assistant, lower the table or raise the vehicle to remove the engine, transmission, front frame and front suspension assembly from the vehicle.
55. Remove the power steering fluid cooler from engine cooling module.
56. Remove the power steering pressure pipe/hose from the power steering pump.
57. Remove the power steering return hose from the power steering gear.
58. Remove the charge air cooler inlet air hose and the charge air cooler outlet hose from the charge air cooler.
59. Remove the radiator inlet hose and the radiator outlet hose from the radiator.
60. Remove the engine cooling module wiring harness from the drivetrain and front suspension frame.
61. Remove the engine wiring harness from the radiator.
62. Remove the engine cooling module from the drivetrain and front suspension frame.
63. Remove both front wheel drive shafts from the transmission.
64. Remove the transmission rear mount fasteners from the drivetrain and front suspension frame.
65. Remove the transmission front mount fasteners from the drivetrain and front suspension frame.
66. Remove the engine and the transmission from the drivetrain and front suspension frame.
67. Remove the transmission rear mount bracket and the transfer case.
68. Remove the engine oil cooler outlet hose.
69. Remove the starter motor.
70. Remove the radiator surge tank engine hose.
71. Install two transmission lift brackets to the transmission housing.
72. Position a second floor crane to the transmission lift brackets and raise the floor crane to partially support the transmission.
73. Remove the transmission from the engine.
74. Remove the transmission front mount.

Installation Procedure

1. Install the transmission front mount.
2. Remove the transmission from the engine.
3. Position a second floor crane to the transmission lift brackets and raise the floor crane to partially support the transmission.
4. Install two transmission lift brackets to the transmission housing.
5. Install the radiator surge tank engine hose.
6. Install the starter.
7. Install the engine oil cooler outlet hose.
8. Install the transmission rear mount bracket and the transfer case.
9. Install the engine and the transmission from the drivetrain and front suspension frame.
10. Install the transmission front mount fasteners from the drivetrain and front suspension frame.
11. Install the transmission rear mount fasteners from the drivetrain and front suspension frame.
12. Connect a floor crane to the engine lift brackets and raise the floor crane to partially support the engine.
13. Install both front wheel drive shafts from the transmission.
14. Install the engine cooling module from the drivetrain and front suspension frame.
15. Install the engine wiring harness from the radiator.
16. Install the engine cooling module wiring harness from the drivetrain and front suspension frame.
17. Install the radiator inlet hose and the radiator outlet hose from the radiator.
18. Install the charge air cooler inlet air hose and the charge air cooler outlet hose from the charge air cooler.
19. Install the power steering return hose to the power steering pump.
20. Install the power steering pressure pipe/hose to the power steering pump.
21. Install the power steering fluid cooler from engine cooling module.
22. With the aid of an assistant, lower the table or raise the vehicle to remove the engine, transmission, front frame and front suspension assembly from the vehicle.
23. Install the front suspension frame fasteners.
24. Raise the lift table or lower the vehicle to support the frame, engine and transmission.
25. Remove the CH-49289 tool.
26. Raise the vehicle.
27. Install the transmission mount fasteners.
28. Install the engine mount bracket to the engine mount support.
29. Lower the vehicle.
30. Install the powertrain lift/support table.
31. Remove the CH-49290 tool.
32. Position a suitable powertrain or engine lift table below the frame, engine and transmission.
33. Raise the vehicle enough to place a suitable lift table under the engine, transmission, front frame and front suspension assembly.
34. If available install the engine shield from the front suspension frame.
35. Install both drivetrain and front suspension frame transmission protectors.
36. Install the exhaust front pipe.
37. Install the relay box (1).





38. Connect the power steering wiring harness connector (2).





39. Connect the engine coolant fan motor wiring harness connectors (1).
40. Connect both front wheel speed sensor electrical connectors. Position and secure both wiring harnesses to the vehicle.
41. Install both front wheel drive shafts from both front wheel bearings and hubs.
42. Install both steering knuckles to both front lower control arms.
43. Install the steering linkage outer tie rod fasteners.
44. Install the stabilizer shaft link fasteners.
45. Install the front wheel drive shaft fasteners.
46. Install the front wheels.
47. Raise and support the vehicle.
48. Install the air conditioning compressor and the condenser hose and the air conditioning evaporator hose.
49. Connect the evaporative pipe quick connector (1).





50. Plug the fuel feed pipe and cap the fuel injection fuel rail to prevent fuel loss or contamination.
51. Install the fuel feed front pipe.
52. Install the heater hose from the water outlet.
53. Relieve the fuel system pressure.
54. Install the heater inlet hose and the heater outlet hose from the heater core.
55. Install the power brake booster pipe (1) from the power brake booster (2).





56. Install the manual transmission shift lever cable to the transmission.
57. Install the engine coolant air bleed hose.
58. Install the radiator surge tank hoses from the radiator surge tank.
59. Install the engine wiring harness (1) to the front compartment fuse block housing (2).





60. Install the engine wiring harness ground connectors (1) from the front end upper tie bar support.





61. Connect the engine wiring harness connectors (1, 2, 3).





62. Filling the cooling system.
63. Install the front bumper fascia.
64. Install the charge air cooler air hose.
65. Install the air cleaner assembly.
66. Install the air cleaner outlet duct.
67. Install the battery tray.
68. Install the engine control module.
69. Evacuate the air conditioning system.
70. Install the engine sight shield.
71. Install the intermediate steering shaft fastener.