Engine Replacement

Engine Replacement

Removal Procedure

1. With the tires in the straight forward position, remove the key from the ignition.
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
4. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (Air Cleaner Outlet Duct Replacement).




5. Secure the cooling module to the upper body structure.
6. Remove the battery and battery box. Refer to Battery Box Replacement (Battery Box Replacement).
7. Disconnect the transmission shifter cable.
8. Disconnect the wiring harness from the underhood junction block.
9. Evacuate the A/C system. Refer to Refrigerant Recovery and Recharging (With HP5) (Refrigerant Recovery and Recharging)Refrigerant Recovery and Recharging (Without HP5) (Refrigerant Recovery and Recharging).




10. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill With HP5) (Service and Repair)Cooling System Draining and Filling (Static Fill Without HP5) (Service and Repair)Cooling System Draining and Filling (GE 47716 Fill With HP5) (Service and Repair)Cooling System Draining and Filling (GE 47716 Fill Without HP5) (Service and Repair).
11. Disconnect the radiator inlet and outlet hoses from the engine.
12. Remove the engine control module (ECM). Refer to Engine Control Module Replacement (Service and Repair).
13. Remove the A/C low pressure tube at the front lift bracket.
14. Disconnect the generator positive cable. Refer to Generator Replacement (LZ4) (Service and Repair)Generator Replacement (LE5) (Service and Repair)Generator Replacement (LY7) (Service and Repair).
15. Disconnect the A/C high pressure switch harness.
16. Remove the A/C tube from the A/C compressor. Refer to Air Conditioning Compressor Hose Replacement (LZ4) (Air Conditioning Compressor Hose Replacement)Air Conditioning Compressor Hose Replacement (LAT) (Air Conditioning Compressor Hose Replacement)Air Conditioning Compressor Hose Replacement (LY7) (Air Conditioning Compressor Hose Replacement)Air Conditioning Compressor Hose Replacement (LE5) (Air Conditioning Compressor Hose Replacement).
17. Disconnect the A/C line from the condenser to compressor.
18. Disconnect the coolant reservoir hose from the engine to reservoir.




19. Remove the heater outlet hose (1).
20. Remove the starter positive cable.
21. Relieve the fuel pressure. Refer to Fuel Pressure Relief (With CH 48027-100) (Service and Repair)Fuel Pressure Relief (Without CH 48027-100) (Service and Repair).
22. Disconnect the fuel feed line. Refer to Fuel Line Replacement - Chassis (Service and Repair).
23. Disconnect the fuel evaporative emission (EVAP) line.
24. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
25. Remove the lower transaxle-to-engine bolts.
26. Remove the torque convertor inspection cover.
27. Remove the torque convertor to flywheel bolts.
28. Remove the transfer case. Refer to Transfer Case Assembly Replacement (LZ4) (Transfer Case Assembly Replacement)Transfer Case Assembly Replacement (LY7) (Transfer Case Assembly Replacement).
29. Remove the front wheels. Refer to Tire and Wheel Removal and Installation (Service and Repair).
30. Remove the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (Service and Repair).
31. Disconnect the transmission cooler lines from the transmission and bracket. Refer to Transmission Mount Bracket Replacement - Rear (Transmission Mount Bracket Replacement - Rear).
32. Remove the left and right tie rod ends from the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement (Steering Linkage Outer Tie Rod Replacement).
33. Remove the left and right stabilizer bar links. Refer to Stabilizer Shaft Link Replacement (Front Suspension).
34. Disconnect the left and right lower ball joints. Refer to Lower Control Arm Ball Joint Replacement (Service and Repair).
35. Remove the left and right axle shaft nuts. Refer to Front Wheel Drive Shaft Replacement (Front Wheel Drive Shaft Replacement).




36. For AWD, remove the propeller shaft completely from the vehicle. Refer to Propeller Shaft Replacement (Service and Repair).

Note: In order to prevent possible SIR system deployment, do not attempt to rotate the steering shaft.

37. Disconnect the steering shaft coupling from the steering gear. Refer to Steering Shaft Coupling Replacement (Service and Repair).
38. Remove the front exhaust pipe. Refer to Catalytic Converter Replacement - Left Side (LZ4) (Catalytic Converter Replacement - Left Side)Catalytic Converter Replacement - Left Side (LY7 ) (Catalytic Converter Replacement - Left Side)Catalytic Converter Replacement - Left Side (LCS) (Catalytic Converter Replacement - Left Side).
39. Remove the 3 front fender pushpins to allow the front fender to flex.
40. Use a paint pen or magic marker to mark the frame to the body position.
41. Support the engine in the cradle with wood blocks.
42. Disconnect the front transmission mount from the body. Refer to Transmission Front Mount Replacement (Transmission Front Mount Replacement).

Note: During the powertrain removal, support the vehicle body by placing a jack at the rear of the vehicle.

43. Position the engine support table under the powertrain assembly.
44. With the table positioned, fully raise the table to contact with the powertrain assembly.
45. Remove the cradle bolts.
46. Slowly lower the table to the floor.
47. Remove the starter. Refer to Starter Replacement (LZ4) (Service and Repair)Starter Replacement (LE5/LAT) (Service and Repair)Starter Replacement (LY7) (Service and Repair).
48. Remove the following components:

1. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement (HP5) (Service and Repair)Air Conditioning Compressor Replacement (LY7) (Service and Repair)Air Conditioning Compressor Replacement (LZ4) (Service and Repair)Air Conditioning Compressor Replacement (LAT, LE5) (Service and Repair).
2. Remove the generator. Refer to Generator Replacement (LZ4) (Service and Repair)Generator Replacement (LE5) (Service and Repair)Generator Replacement (LY7) (Service and Repair).
3. Remove the front covers. Refer to Engine Front Cover Replacement (Service and Repair).
4. Remove the rocker covers. Refer to Valve Rocker Arm Cover Replacement - Left Side (Valve Rocker Arm Cover Replacement - Left Side) and Valve Rocker Arm Cover Replacement - Right Side (Valve Rocker Arm Cover Replacement - Right Side).
5. Remove the catalytic converters. Refer to Catalytic Converter Replacement - Left Side (LZ4) (Catalytic Converter Replacement - Left Side)Catalytic Converter Replacement - Left Side (LY7 ) (Catalytic Converter Replacement - Left Side)Catalytic Converter Replacement - Left Side (LCS) (Catalytic Converter Replacement - Left Side) and Catalytic Converter Replacement - Right Side (LZ4) (Catalytic Converter Replacement - Right Side)Catalytic Converter Replacement - Right Side (LY7) (Catalytic Converter Replacement - Right Side)Catalytic Converter Replacement - Right Side (LCS) (Catalytic Converter Replacement - Right Side).
6. Remove the timing chain. Refer to Camshaft Timing Chain and Sprocket Replacement (Service and Repair).
7. Remove the cylinder heads. Refer to Cylinder Head Replacement - Left Side (Service and Repair) and Cylinder Head Replacement - Right Side (Service and Repair).

49. Remove the front transmission mount from the engine. Refer to Transmission Front Mount Replacement (Transmission Front Mount Replacement).
50. Remove the right engine mount. Refer to Engine Mount Replacement (Service and Repair).
51. Separate the engine from the transmission.

Installation Procedure

1. Align the engine to the transmission.





Caution: Refer to Fastener Caution (Fastener Caution).

2. Apply sealant to the two upper transmission-to-engine bolts only, and install the transmission-to-engine mounting bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers (Specifications) for the correct part number.
Tighten the bolts to 64 Nm (47 lb ft).
3. Install the right engine mount. Refer to Engine Mount Replacement (Service and Repair).
4. Install the front transmission mount to the engine. Refer to Transmission Front Mount Replacement (Transmission Front Mount Replacement).
5. Install the following components:

1. Install the cylinder heads. Refer to Cylinder Head Replacement - Left Side (Service and Repair) and Cylinder Head Replacement - Right Side (Service and Repair).
2. Install the timing chain. Refer to Camshaft Timing Chain and Sprocket Replacement (Service and Repair).
3. Install the catalytic converters. Refer to Catalytic Converter Replacement - Left Side (LZ4) (Catalytic Converter Replacement - Left Side)Catalytic Converter Replacement - Left Side (LY7 ) (Catalytic Converter Replacement - Left Side)Catalytic Converter Replacement - Left Side (LCS) (Catalytic Converter Replacement - Left Side) and Catalytic Converter Replacement - Right Side (LZ4) (Catalytic Converter Replacement - Right Side)Catalytic Converter Replacement - Right Side (LY7) (Catalytic Converter Replacement - Right Side)Catalytic Converter Replacement - Right Side (LCS) (Catalytic Converter Replacement - Right Side).
4. Install the rocker covers. Refer to Valve Rocker Arm Cover Replacement - Left Side (Valve Rocker Arm Cover Replacement - Left Side) and Valve Rocker Arm Cover Replacement - Right Side (Valve Rocker Arm Cover Replacement - Right Side).
5. Install the front covers. Refer to Engine Front Cover Replacement (Service and Repair).
6. Install the generator. Refer to Generator Replacement (LZ4) (Service and Repair)Generator Replacement (LE5) (Service and Repair)Generator Replacement (LY7) (Service and Repair).
7. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement (HP5) (Service and Repair)Air Conditioning Compressor Replacement (LY7) (Service and Repair)Air Conditioning Compressor Replacement (LZ4) (Service and Repair)Air Conditioning Compressor Replacement (LAT, LE5) (Service and Repair).

6. Install the starter. Refer to Starter Replacement (LZ4) (Service and Repair)Starter Replacement (LE5/LAT) (Service and Repair)Starter Replacement (LY7) (Service and Repair).
7. Install the powertrain assembly to the vehicle.
8. Install the cradle bolts. Refer to Frame Replacement (4T45-E Transmission) (Frame Replacement (4T45-E Transmission))Frame Replacement (6T70 Transmission) (Frame Replacement (6T70 Transmission))Frame Replacement (2MT70 Transmission) (Frame Replacement (2MT70 Transmission)).
9. Remove the engine support table.
10. Install the front transmission mount bolts to the body. Refer to Transmission Front Mount Replacement (Transmission Front Mount Replacement).
11. Remove the wood blocks from the cradle.
12. Install the lower transaxle-to-engine bolts and tighten to 75 Nm (55 lb ft).
13. Install the transfer case. Refer to Transfer Case Assembly Replacement (LZ4) (Transfer Case Assembly Replacement)Transfer Case Assembly Replacement (LY7) (Transfer Case Assembly Replacement).
14. Install the torque convertor-to-flywheel bolts and tighten to 62 Nm (46 lb ft).
15. Install the torque convertor inspection cover and tighten the bolts to 12 Nm (106 lb in).
16. Install the 3 front fender pushpins.
17. Install the front exhaust pipe. Refer to Catalytic Converter Replacement - Left Side (LZ4) (Catalytic Converter Replacement - Left Side)Catalytic Converter Replacement - Left Side (LY7 ) (Catalytic Converter Replacement - Left Side)Catalytic Converter Replacement - Left Side (LCS) (Catalytic Converter Replacement - Left Side).
18. Connect the steering shaft coupling from the steering gear. Refer to Steering Shaft Coupling Replacement (Service and Repair).
19. Install the propeller shaft. Refer to Propeller Shaft Replacement (Service and Repair).
20. Install the left and right axle shaft nuts. Refer to Front Wheel Drive Shaft Replacement (Front Wheel Drive Shaft Replacement).
21. Connect the left and right lower ball joints. Refer to Lower Control Arm Ball Joint Replacement (Service and Repair).
22. Install the left and right stabilizer bar links. Refer to Stabilizer Shaft Link Replacement (Front Suspension).
23. Install the left and right tie rod ends to the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement (Steering Linkage Outer Tie Rod Replacement).
24. Connect the transmission cooler lines to the transmission and bracket. Refer to Transmission Mount Bracket Replacement - Rear (Transmission Mount Bracket Replacement - Rear).
25. Install the left wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (Service and Repair).
26. Install the front tires. Refer to Tire and Wheel Removal and Installation (Service and Repair).
27. Lower the vehicle.




28. Install the fuel EVAP line.
29. Connect the fuel feed line. Refer to Fuel Line Replacement - Chassis (Service and Repair).
30. Install the starter positive cable and tighten to 10 Nm (89 lb in).




31. Install the heater outlet hose (1).
32. Install the A/C tube to the A/C compressor. Refer to Air Conditioning Compressor Hose Replacement (LZ4) (Air Conditioning Compressor Hose Replacement)Air Conditioning Compressor Hose Replacement (LAT) (Air Conditioning Compressor Hose Replacement)Air Conditioning Compressor Hose Replacement (LY7) (Air Conditioning Compressor Hose Replacement)Air Conditioning Compressor Hose Replacement (LE5) (Air Conditioning Compressor Hose Replacement).
33. Connect the coolant reservoir hose from the engine to reservoir.
34. Connect the A/C line from the condenser to compressor.
35. Connect the A/C high pressure switch harness.
36. Connect the generator positive cable and nut and tighten to 12 Nm (106 lb in).
37. Install the A/C lower pressure tube at the front lift bracket. Refer to Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement (HP5) (Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement)Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement (LAT) (Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement)Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement (LE5, LZ4, LY7) (Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement).
38. Install the ECM. Refer to Engine Control Module Replacement (Service and Repair).




39. Connect the radiator inlet and outlet hoses to the engine.
40. Fill the vehicle with coolant. Refer to Cooling System Draining and Filling (Static Fill With HP5) (Service and Repair)Cooling System Draining and Filling (Static Fill Without HP5) (Service and Repair)Cooling System Draining and Filling (GE 47716 Fill With HP5) (Service and Repair)Cooling System Draining and Filling (GE 47716 Fill Without HP5) (Service and Repair).
41. Connect the wiring harness to the underhood junction block. Refer to Underhood Electrical Center or Junction Block Replacement (HP7) (Service and Repair)Underhood Electrical Center or Junction Block Replacement (HP5) (Service and Repair).
42. Connect the transmission shifter cable.




43. Install the battery box and battery. Refer to Battery Box Replacement (Battery Box Replacement).
44. Remove the cooling module support.
45. Install the air outlet duct assembly. Refer to Air Cleaner Outlet Duct Replacement (Air Cleaner Outlet Duct Replacement).
46. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
47. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
48. Perform the throttle learn procedure. Refer to Throttle/Idle Learn (Throttle Learn).