Engine Replacement

ENGINE REPLACEMENT

TOOLS REQUIRED
- J43828 Lower Control Arm Separator
- J45341 Axle Shaft Removal Tool
- SA91100C Tie Rod Tool
- SA9127E Gauge Bar Set
- SA9805E Fuel Line Disconnect Set

REMOVAL

NOTICE: 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.
2. Remove battery cover, and battery.





3. Remove air cleaner assembly.





4. Remove Underhood Fuse Block (UHFB) fuse cover by separating clips on each side.
5. Remove UHFB fuse cover.
6. Remove inner UHFB fuse cover.
7. Loosen 3 connector through bolts at top of UHFB.
8. Remove battery and electronic power steering feed wire connection nut and remove wire from UHFB stud.
9. Release tabs on each side of UHFB with a screwdriver.
10. Raise UHFB from connectors, disconnect side electrical connectors.
11. Remove UHFB from vehicle.
12. Remove battery cable and harness attachment clips on side of battery tray/UHFB bracket assembly.
13. Remove main connectors from UHFB housing.
14. Lay battery positive cable over engine (battery cables will be removed with powertrain assembly).
15. Disconnect electrical connectors at transaxle controller (TC) near brake booster.
16. Disconnect electrical connector for rear O2 sensor and cut tie strap to heater hoses.
17. Remove vacuum hose with check valve from brake booster and lay across engine.
18. Disconnect main engine harness (Grey connector) and lay over engine assembly. This will allow engine harness to be removed with powertrain.
19. Remove UHFB and battery tray bolts.
20. Remove UHFB and battery tray and ground wire.
21. Disconnect shifter cable from PRNDL switch by using a screwdriver. Slightly pry between the shifter cable plastic retainer and PRNDL switch.
22. Drain Coolant.
23. Disconnect upper radiator hose at engine cylinder head.
24. Disconnect lower radiator hose at radiator.
25. Disconnect De-gas hose at surge tank.
26. Disconnect surge hose at bottom of surge tank.
27. Disconnect heater hoses from heater core at front of dash





28. Relieve fuel system pressure using Gauge Bar Set SA9127E.
29. Disconnect Gauge Bar Set SA9127E after pressure has been relieved.
30. Disconnect fuel transfer line at quick connect from fuel line using Fuel Line Disconnect Set SA9805E (or equivalent).
31. Disconnect purge hoses at purge solenoid.

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

32. Using long tie straps secure radiator/condenser fan assembly to body.





33. Perform an evacuation of A/C system.
34. Disconnect A/C transducer and compressor.

CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON THE HOIST. TO HELP AVOID PERSONAL INJURY WHEN IL VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.

35. Raise vehicle.





36. Remove Front LH wheel.
37. Remove from LH wheel inner splash shield and tire assembly.

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.

38. Install a piece of hardwood tin x 2 in x din piece of hard wood between transaxle case and engine cradle assembly.
39. Remove front RH wheel and tire assembly.
40. Remove wheel inner splash shield.

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

41. Remove compressor and support A/C line.
42. Remove push pins that retain air deflector assembly to cradle.

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

IMPORTANT: Fluid will leak when lines are disconnect, place a dip pan to collect transaxle oil.
43. Disconnect transaxle lines from transaxle.





44. Remove exhaust manifold to pipe flange bolts.
45. Remove exhaust pipe to muffler pipe nuts.
46. Remove converter pipe assembly and support muffler and pipe assembly.





47. Remove propshaft bolts at Power Takeoff Unit (PTU).
48. Remove propshaft bolt at rear axle assembly.
49. Remove propshaft support bracket to body bolts.
50. Remove propshaft assembly.
51. Remove shifter cable bracket assembly nut and free bracket with cable from transaxle.
52. Remove steering gear to intermediate shaft bolt.





53. Remove tie rod to knuckle nuts.





54. Separate tie rod assemblies from knuckle assemblies using Tie Rod Tool SA91 100C (or equivalent).
55. Remove lower control arm cotter pins and nuts to knuckle assembly.
56. Separate lower control arms to knuckle assemblies by using Lower Control Arm Separator J43828 (or equivalent).





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

57. Remove lower stabilizer link nuts to stabilizer bar.





58. Disconnect LH axle shaft assembly from transaxle.





59. Disconnect RH shaft assembly from Intermediate Drive shaft using Axle Shaft Removal Tool 145341 (or equivalent) with appropriate slide tool.
60. Support axle shaft by using tie straps.
61. Lower vehicle.
62. Remove RH engine mount to engine bracket bolts. Engine should rest on wood blocks.
63. Remove LH transaxle mount to transaxle bolts. Transaxle should rest on wood blocks.

CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON THE HOIST. TO HELP AVOID PERSONAL, INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL, SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.

64. Raise vehicle.
65. 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 assembly during removal.

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

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

68. 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 Alignment pins with cradle assembly.

NOTICE: Body to Cradle bolts area one time use fastener and should be discard after removal.

3. Position cradle guide pins into location and install new cradle to Body bolts.
Torque:
Frame to Body Bolts: 155 N.m (114 ft. lbs.)
4. Lower vehicle.
5. Install RH engine mount to engine bracket bolts.
Torque:
RH Engine Mount to Engine Bracket Bolts: 50 N.m (37 ft. lbs.)
6. Install LH transaxle mount to transaxle bolts.
Torque:
LH Transaxle Mount-to-Engine Bracket Bolts: 50 N.m (37 ft. lbs.)
7. Lower vehicle.
8. Remove wood blocks between cradle and powertrain.

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

9. Swing axle shafts into position and fully seat in transaxle and hearing. Slight taps may be required on back side of CV axle housing.
10. Position strut assemblies onto lower control arms.





11. Install lower control arm nut.
12. Verify axles are fully seated.
13. Position stabilizer link into position and install nut.
14. Install stabilizer nut.
Torque:
Stabilizer Link-to-Strut: 65 N.m (48 ft. lbs.)
15. Install tic rod end into strut knuckle assembly
Torque:
Tie Rod-to-Knuckle Assembly Nut: 50 N.m (37 ft. lbs.)
16. Secure brake line-to-cradle assembly.
17. Install steering shaft-to-intermediate shaft.
18. Install steering shaft-to-intermediate shaft bolt.
Torque:
Steering Shaft-to-Rack Bolt: 34 N.m (25 ft. lbs.)





19. Install propshaft into position hand tighten center bearing nuts.
20. Instal l propshaft into position.
21. Install propshaft-to-PTU bolts.
Torque:
Propshaft-to-PTU Bolts: 25 N.m (19 ft. lbs.)
22. Install propshaft into rear axle assembly.
23. Install propshaft to rear axle bolts.
Torque:
Propshaft-to-Rear Axle Bolts: 50 N.m (37 ft. lbs.)
24. Tighten propshaft support bearing bolts:
Torque:
Propshaft Support Bearing Bolts: 25 N.m (19 ft. lbs.)
25. Install propshaft support strap.
Torque:
Propshaft Support Strap: 25 N.m (19 ft. lbs.)





26. Install shifter cable bracket-to-transaxle.
27. Connect transaxle lines-to-transaxle.
Torque:
Transaxle Cooler Lines-to-Transaxle Stud: 20 N.m (15 ft. lbs.)
Torque:
Transaxle Cooler Lines-to-Transaxle Nut: 10 N.m (7 ft. lbs.)
28. Install 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: 30 N.m (22 ft. lbs.)
31. Route O2 harness into position at heat shield.
32. Install A/C hoses-to-compressor.
33. Connect A/C compressor harness.
34. Connect A/C pressure transducer.
35. Attach front air deflector-to-cradle assembly.





36. Install right inner splash shield.
37. Install right wheel and tire assembly, and hand tighten wheel nuts.
38. Install LH inner splash shield.
39. Install left wheel and hand tighten wheel nuts.
40. Lower vehicle.
Torque:
Wheel Nuts: 125 N.m (92 ft. lbs.)
41. Connect shifter cable to PRNDL switch.
42. Adjust PRNDL switch.
43. Connector heater hoses from heater core at front of dash.
44. Connect purge hose at purge solenoid.
45. Connect fuel transfer line at quick connect to fuel line.
46. Connect surge hose at bottom of surge tank.
47. Connect De-gas hose at Surge tank.
48. Connect lower radiator hose at coolant pipe.
49. Connect upper radiator hose at engine cylinder head.
50. Install engine ground to body bolt.
Torque:
Engine Ground-to-Body Bolt: 20 N.m (15 ft. lbs.)





51. Install UHFB and battery tray.
52. Install UHFB and battery tray bolts.
Torque:
Battery Tray Bolts: 16 N.m (11 ft. lbs.)
53. Route engine harness intake position and install main engine and body Harness connectors into UHFB housing.
54. Snap connectors into position in UHFB.
55. Connector both electrical connectors underneath UHFB.

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

56. Install UHFB into while aligning UHFB with connectors.
57. Snap UHFB into position.
58. Tighten UHFB connector bolts.
Torque:
UHFB Connector Bolts: 20 N.m (15 ft. lbs.)
59. Install battery and Electronic Power Steering (EPS) feed wire to UHFB stud and tighten nut.
Torque:
Battery Positive-to-UHFB Nut: 15 N.m (11 ft. lbs.)
60. Install UHFB fuse cover into position.
61. Connect electrical connectors to TCM.
62. Install battery cable and harness attachment clips on side of battery tray/UHFB bracket assembly.





63. Install battery and cover.
64. Install brake vacuum hose into booster.
65. Connect rear O2 sensor connector
66. Tighten clamp at air cleaner assembly.
67. Connect negative battery cable.
Torque:
Battery Terminal Bolt: 17 N.m (13 ft. lbs.)
68. Check for proper oil level.
69. Start engine and fill transaxle fluid.

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.

70. Fill engine coolant.
71. Check for leaks.
72. If excessive
73. Charge A/C system.
74. Verify wheel adjustment is within specifications.