Engine Replacement

ENGINE REPLACEMENT

TOOLS REQUIRED
- J 36346 Fascia Retainer Remover
- J 43828 Lower Control Arm Separator
- J 44811 Accessory Belt Tensioner Unloader
- J 45341 Axle Shaft Removal
- SA91100C Tie Rod
- SA9127E Gauge Bar Set
- SA9805E Line Disconnect Set

REMOVAL





CAUTION: TO AVOID FROM HAVING UNSTABLE VEHICLE ON THE HOIST, BE SURE TO PROPERLY POSITION VEHICLE. THIS SHOULD BE CONSIDERED WHEN MAJOR COMPONENTS ARE BEING REMOVED (ENGINE AND TRANSAXLE ASSEMBLIES).

1. Disconnect negative battery cable and remove battery.
2. Disconnect Intake Air Temperature (IAT) sensor connector.
3. Loosen clamp at air cleaner assembly.
4. Remove pushpin attachment from outlet resonator/duct assembly to support bracket.
5. Loosen clamp at throttle body assembly.
6. Disconnect PVC fresh air vent hose at cam cover.
7. Remove outlet resonator/duct assembly.





8. Cover throttle body opening with a shop towel. Use shop air to remove any dirt around throttle body and intake manifold to cylinder head.





9. Remove Underhood Fuse Block (UHFB) fuse cover by separating clips on each side.
10. Remove UHFB fuse cover.
11. Remove inner UHFB fuse cover.
12. Loosen three connector through bolts at top UHFB.
13. Remove battery and electronic power steering feed wire connection nut and remove wire from UHFB stud.
14. Release tabs on each side of UHFB with a screwdriver.
15. Raise UHFB from connectors. Disconnect electrical connectors on side of UHFB.
16. Remove UHFB from vehicle.
17. Remove battery cable and harness attachment clips on side of battery tray/UHFB bracket assembly.
18. Remove main connectors from UHFB housing.
19. Lay battery positive cable over engine. (Battery cables will be removed with powertrain assembly.)
20. Remove electrical harness clips to battery tray.
21. Remove UHFB and battery tray bolts.
22. Remove UHFB and battery tray.





23. Disconnect electrical connectors at Transaxle Controller (TCM) near brake booster (if equipped).
24. Remove engine-to-body ground bolt.
25. Disconnect connector for rear O2 sensor.
26. Remove vacuum hose with cheek valve from booster and lay across engine.
27. Disconnect 8-way electrical connector.
28. Remove main engine harness (Grey connector) and lay over engine assembly. (This will allow engine harness to be removed with powertrain.)

NOTICE: Do not remove shiftier cable from bracket before removing cable from transaxle range switch. Damage to manual shift linkage may occur.

29. If equipped with automatic range transaxle, disconnect shifter cable from transaxle range switch by using a screwdriver. Slightly pry between shifter cable plastic retainer and transaxle range switch. (Automatic Only)





NOTICE: Do not use too much force when disconnecting the shift cables or damage may result.

30. Disconnect shift lever cables from shift control housing by prying with even pressure using a Fascia Retainer Remover J36346 (or equivalent). (M/T Only)
31. Disconnect shift lever cables from shift lever cable bracket. (M/T Only)





32. Disconnect pressure line from clutch actuator cylinder by removing C-clip then pulling line away from clutch actuator cylinder. (M/T Only)





33. Disconnect back-up lamp switch (1) and front wheel speed sensor (2). (M/T Only)





IMPORTANT: Place shop towel on generator to prevent coolant from entering the generator assembly.

34. Drain coolant.
35. Disconnect upper radiator hose at engine cylinder head.





36. Disconnect lower radiator hose at coolant pipe.





37. Disconnect de-gas hose at surge tank.
38. Disconnect surge hose at bottom of surge tank.
39. Disconnect heater hoses from heater core at front of dash.





40. Relieve fuel system pressure using Gauge Bar Set SA9127E.
41. Disconnect Gauge Bar Set SA9127E after pressure has been relieved.
42. Remove safety clip and disconnect fuel transfer line at quick connect from fuel line using Line Disconnect Set SA9805E.
43. Disconnect purge hoses at rear of purge solenoid.
44. Remove headlamp assemblies.





IMPORTANT: Radiator/condenser/fan assembly will stay in vehicle during engine removal.

45. Using long lie straps, secure radiator/condenser fan assembly to radiator support assembly.





46. Raise vehicle.
47. Remove front Left-Hand (LH) wheel.
48. Remove front LH wheel inner splash shield.

IMPORTANT: A piece of hardwood should be used between transaxle case and cradle assembly. This wood will support transaxle when LH mount bolts are removed.

49. Install a piece of hardwood 1 in. x 2 in. x 4 in. between transaxle case and engine cradle assembly.
50. Remove front Right Hand (RH) wheel.
51. Remove wheel inner splash shield.

NOTICE: Do not install wood under oil pan plug boss. Damage to oil pan may occur.

IMPORTANT: A piece of hardwood should be used between oil pan assembly and engine cradle. This wood will support engine when right-hand mount bolts are removed.

52. Install a piece of hardwood 1 in. x 2 in. x 4 in. between engine oil pan and engine cradle assembly near crankshaft.





53. Install Accessory Belt Tensioner Unloader J44811 tool onto tensioner.
54. Remove accessory drive belt.
55. Disconnect electrical connector at A/C compressor.
56. Disconnect electrical connector at A/C pressure transducer (on line).
57. Remove A/C compressor bolts.
58. Support compressor and line assembly to body with support straps.
59. Remove pushpins that retain air deflector assembly to cradle.





IMPORTANT: When transaxle lines are disconnected, new seals must be installed into transaxle to prevent potential for leak.

IMPORTANT: Fluid will leak when lines are disconnected. Place a drip pan to collect transaxle oil.

60. Drain transaxle fluid.
61. Disconnect transaxle lines from transaxle. (Automatic Only)
62. Disconnect rear O2 sensor.
63. Remove exhaust pipe-to-manifold flange bolts.
64. Remove exhaust pipe to intermediate pipe nuts.
65. Remove converter pipe assembly and support intermediate pipe assembly.
66. Remove propshaft bolts to Power Takeoff Unit (PTU) -AWD Only.
67. Remove propshaft bolts at rear axle assembly - AWD Only.
68. Remove propshaft support bracket-to-body bolts -AWD Only.
69. Remove propshaft assembly - AWD Only.

NOTICE: Do not remove cable from bracket before disconnecting shifter cable from transaxle range switch. Damage to manual shift shaft may occur. (Automatic Only)

70. If equipped with automatic, remove shifter cable from bracket assembly. (Automatic Only)





71. Remove steering gear to intermediate shaft bolt.





72. Remove tie rod to knuckle nuts.
73. Separate tie rod assemblies from knuckle assemblies using Tie Rod SA91100C tool.
74. Remove lower control arm cotter pins and nuts to knuckle assembly.
75. Separate lower control arms to knuckle assemblies by using Lower Control Arm Separator J43828.

IMPORTANT: Stabilizer links will stay in vehicle connected to strut assembly on engine removal.

76. Remove lower stabilizer link nuts to stabilizer bar.
77. Remove left-hand axle shaft assembly from transaxle.
78. Disconnect right-hand shaft assembly from intermediate drive shaft using Axle Shaft Removal J45341 tool with appropriate slide tool.
79. Lower vehicle.
80. Remove right-hand engine mount to engine bracket bolts. Engine should rest on wood blocks.





81. Remove left-hand transaxle mount to transaxle bolts. transaxle should rest on wood blocks.
82. Raise vehicle on hoist.





IMPORTANT: During powertrain removal support vehicle body by placing a jack at rear of vehicle.

83. Position engine support table under powertrain assembly.

IMPORTANT: Blocks of wood can be used between the front of cradle and oil pan to table to level powertrain during removal.

84. With table positioned, fully raise table to contact with powertrain assembly.
85. Remove cradle to body bolts.

IMPORTANT: When lowering engine/transaxle assembly, verify all brake lines, shifter cable and other components are free during removal.

86. Lower engine table and raise body on hoist until engine/transaxle and cradle assembly is free from vehicle.


INSTALLATION





1. With powertrain supported on jacking table, raise powertrain into position.

NOTICE: If radiator assembly is not properly positioned to cradle, damage could occur.

2. Raise powertrain assembly into position. Align lower radiator aligN.ment pins with cradle assembly. Be sure all hoses and electrical harnesses are correctly routed and free from the loading path of powertrain assembly.
3. Raise transaxle into vehicle to align input shaft to the center of clutch. Guide transaxle into position, rotate back and forth to align input Shaft splines to clutch disc. (M/T Only)

NOTICE: Body-to-cradle bolts are a one time use fastener and should be discarded after removal.

4. Position cradle guide pins into location and install new cradle-to-body bolts.
Torque:
Frame-to-Body Bolts: 155 N.m (114 ft. lbs.)
5. Lower vehicle.





6. Install Right Hand (RH) engine mount-to-engine bracket bolts.
Torque:
Engine Mount-to-Engine Bracket Bolts: 50 N.m (37 ft. lbs.)
7. Install RH engine mount assembly and nuts.
Torque:
Engine Mount-to-Engine Body Nuts: 110 N.m (81 ft. lbs.)





8. Install Left-Hand (LH) transaxle mount to transaxle bolts.
Torque:
Left-Hand (LH) transaxle Mount-to-Engine Bracket Bolts: 50 N.m (37 ft. lbs.)
9. Raise vehicle.
10. Remove wood blocks between cradle and powertrain.

NOTICE: Care should be used to avoid damaging transaxle and bearing races when axles are seated.

11. Swing axle shafts into position and fully seat axles into transaxle.
12. Position strut assemblies onto lower control arms.
13. Install lower control arm nut.
Torque:
Lower Control Arm-to-Knuckle Nut: 10 N.m (89 inch lbs.) +150 degrees
14. Verily axles are fully seated.
15. Position stabilizer link into position and install nut.
16. Install stabilizer nut.
Torque:
Stabilizer Link to Strut: 65 N.m (48 ft. lbs.)





17. Install tie rod end into strut knuckle assembly.
Torque:
Tie Rod to Knuckle Assembly: 50 N.m (37 ft. lbs.)





18. Install steering Shaft-to-intermediate shaft.
19. Install steering Shaft-to-intermediate shaft bolt.
Torque:
Steering Shaft-to-Rack Bolt: 34 N.m (25 ft. lbs.)
20. Install propshaft into position. Hand-tighten center bearing nuts - AWD Only.
21. Install propshaft into position - AWD Only.
22. Install Propshaft-to-PTU bolts - AWD Only.
Torque:
Propshaft-to-PTU Bolts: 25 N.m (19 ft. lbs.)
23. Install propshaft into rear axle assembly - AWD Only.
24. Install propshaft to rear module bolts - AWD Only.
Torque:
Propshaft-to-Rear Module Bolts: 50 N.m (37 ft. lbs.)
25. Tighten propshaft support bearing bolts - AWD Only.
Torque:
Propshaft Support Bearing Bolts: 25 N.m (19 ft. lbs.)
26. Install propshaft support strap - AWD Only.
Torque:
Prop Shaft Guard Strap: 25 Am (19 ft. lbs.)





27. Connect transaxle lines to transaxle.
Torque:
Transaxle Cooler Lines-to-Transaxle Stud: 20 N.m (15 ft. lbs.) (Automatic Only)
Torque:
Transaxle Cooler Lines-to-Transaxle Nut: 10 N.m (7 ft. lbs.) (Automatic Only)
28. Install gasket and down pipe to intermediate pipe assembly.
29. Hand-tighten nuts.
30. Install gasket and down pipe to exhaust manifold.
Torque:
Down Pipe-to-Exhaust Manifold Nuts: 30 N.m (22 ft. lbs.)
Torque:
Down Pipe-to-Intermediate Pipe Nuts: 50 N.m (37 ft. lbs.)
31. Route O2 harness into position at heat shield.





32. Install A/C compressor to engine block.
Torque:
A/C Compressor-to-Block Bolt: 25 N.m (18 ft. lbs.)
33. Connect A/C compressor harness to compressor.
34. Connect A/C pressure transducer to sensor.





35. Install route belt around alternator and A/C compressor.
36. Install Accessory Drive Belt tool J39914 onto tensioner and unload spring tension from tensioner while positioning belt.
37. Release tensioner and remove tool.
38. Attach front air deflector to cradle assembly.
39. Route and install shifter cable into bracket.
40. Install right engine inner splash shield.
41. Install right wheel and hand-tighten wheel nuts.
42. Install Left-Hand (LH) inner splash shield.
43. Install left wheel and hand-tighten wheel nuts.
44. Lower vehicle.
Torque:
Wheel Nuts: 125 N.m (92 ft. lbs.)
45. Connect shifter cable to transaxle range switch. Adjustment is required. (Automatic Only)





46. Connect clutch hydraulic line to actuator cylinder by inserting and pushing in C-clip until it stops. (M/T Only)
47. Connect shift cables into shift cable bracket. (M/T Only)
48. Connect shift cable ends to transaxle. (M/T Only)
49. Connect heater hoses to heater core at front of dash.
50. Connect purge hose at purge solenoid.
51. Connect fuel transfer line to quick connect to fuel line.
52. Connect surge hose at bottom of surge tank.
53. Connect de-gas hose at surge tank.





54. Connect lower radiator hose at coolant pipe.
55. Connect upper radiator hose at engine cylinder head.
56. Cut radiator support straps and remove.





57. Install headlamp assemblies and torque bolts.
58. Route engine ground under A/C line.
59. Install engine ground-to-body bolt.
Torque:
Engine Ground-to-Body Bolt: 20 N.m (15 ft. lbs.)
60. Install Under Hood Fuse Block (UHFB) and battery tray.
61. Install UHFB and battery tray bolts.
Torque:
Battery Tray Bolts: 16 N.m (11 ft. lbs.)
62. Route engine harnesses into position and install main engine and body harness connectors into UHFB housing.





63. Snap connectors into position in UHFB.
64. Connect both electrical connectors underneath UHFB.

IMPORTANT: Make sure engine and body harnesses are properly positioned to avoid damage to harness.

65. Install UHFB while aligning UHFB with connectors.
66. Snap UHFB into position.
67. Tighten UHFB connector bolts.
Torque:
UHFB Connector Bolts: 4 N.m (35 inch lbs.)
68. Install battery and Electronic Power Steering (EPS) feed wire to UHFB stud and tighten nut.
Torque:
Battery Positive-to-UHFB Stud: 10 N.m (89 inch lbs.)
69. Install UHFB fuse cover into position.
70. Connect electrical connectors to TCM (if equipped).
71. Install battery cable and harness attachment clips on side of battery tray/UHFB bracket assembly.
72. Install battery and cover.
73. Install brake vacuum hose into booster.
74. Connect rear O2 sensor connector.
75. Secure rear O2 sensor to body clips (near air cleaner assembly).
76. Remove shop towel from throttle body opening.





77. Position outlet resonator/duct assembly into position.
78. Connect PCV fresh air vent hose assembly.
79. Tighten clamp at throttle body assembly.
80. Position outlet resonator/duct assembly up with support bracket and install pushpin.
81. Tighten clamp at air cleaner assembly.
82. Connect Intake Air Temperature (IAT) sensor connector.
83. Connect negative battery cable.
Torque:
Battery Terminal Bolt: 17 N.m (13 ft. lbs.)





NOTICE: All entrapped air must be purged from the powertrain cooling system before final coolant level can be determined. Proper coolant level is critical to avoid engine damage.

84. Fill coolant system.
85. Start engine and fill automatic transaxle fluid.
86. Check for leaks.
87. If excessive engine idle vibration is noticed, mount adjustment procedure can be performed.
88. Verify wheel aligN.ment is within specifications.