Engine Replacement - Automatic Transaxle
- TOOLS REQUIRED- SA9127E Gauge Bar Adapter
- 16-18/205049 Floor Crane w/Adjusting Sling
REMOVAL
1. Remove Battery.
2. Disconnect main wire feed to fuse block.
3. Disconnect main ground on left fender well.
4. Remove intake air temperature (IAT) electrical connection.
5. Remove air cleaner lid and inlet duct.
6. Remove air box.
7. Disconnect purge hose from throttle body and route away from engine.
8. Disconnect the following electrical connections:
- purge solenoid electrical
- rear 02 sensor
- main harness connector from master cylinder
9. Remove cowl cover.
10. Remove PCM boot from cowl.
11. Disconnect PCM electrical connectors and secure to engine.
12. Remove fuse block lid.
13. Disconnect engine harness main conductor from bottom of fuse block.
14. Remove battery tray and fuse block tray.
15. Disconnect cruise control and throttle cables.
16. Remove coolant reservoir cap.
17. Disconnect brake assist vacuum line from throttle body and route away from engine.
18. Relieve fuel pressure.
19. Disconnect fuel lines and secure away from engine.
20. Disconnect EVAP purge hose at EVAP purge solenoid.
CAUTION: MAKE SURE THAT VEHICLE IS PROPERLY AND SQUARELY POSITIONED ON HOIST. TO HELP AVOID PERSONAL INJURY, PROVIDE SUPPORT TO OPPOSITE END OF VEHICLE THAT COMPONENTS WILL BE REMOVED FROM.
21. Raise vehicle.
22. Drain engine coolant.
23. Disconnect heater hoses at lower cowl.
24. Remove starter.
25. Remove torque converter bolts.
26. Remove exhaust system from catalytic converter forward.
27. Disconnect transmission nose bracket.
28. Remove A/C compressor mounting bolts and secure to frame rail.
NOTICE: It is not necessary to disconnect A/C lines.
29. Disconnect lower engine to transmission bell housing bolts, do not remove upper bolts at this time.
30. Lower vehicle.
31. Remove main hose to coolant reservoir from engine inlet adapter.
32. Remove lower radiator hose from engine.
33. Remove upper radiator hose from engine.
34. Drain power steering fluid by removing smaller hose from under reservoir.
35. Disconnect metal power steering line.
36. Attach engine lift hoist to lift hooks on engine and support engine weight.
37. Support weight of transaxle with floor jack or jack stand.
38. Remove right front engine mount from wheel housing.
39. Remove engine mount bracket from engine.
40. Remove upper bell housing bolts.
41. Lift engine out of vehicle.
INSTALLATION
1. Support transaxle with floor jack or jack stand.
2. Lower engine into vehicle and guide to mate with dowel pins on transmission.
3. When engine and transmission are aligned on shuffle pins install upper bell housing bolts. Do not torque at this time.
4. Install engine mount bracket onto engine and install bolts.
- Torque: 90 Nm (66 ft. lbs.)
5. Install right front engine mount and install bolts.
- Torque: 55 Nm (41 ft. lbs.)
6. Install transmission nose bracket bolts.
- Torque: 35 Nm (26 ft. lbs.)
7. Remove engine lift hoist.
8. Attach metal power steering line.
9. Attach lower power steering hose to bottom of power steering reservoir.
10. Install upper radiator hose.
11. Install lower radiator hose.
12. Attach main coolant reservoir hose to engine.
CAUTION: MAKE SURE THAT VEHICLE IS PROPERLY AND SQUARELY POSITIONED ON HOIST. TO HELP AVOID PERSONAL INJURY, PROVIDE SUPPORT TO OPPOSITE END OF VEHICLE THAT COMPONENTS WILL BE REMOVED FROM.
13. Raise vehicle.
14. Install lower engine to transmission bell housing bolts and tighten.
- Torque: 65 Nm (48 ft. lbs.)
15. Install torque converter bolts.
- Torque: 45 Nm (33 ft. lbs.)
16. Install starter.
17. Connect heater hoses at lower cowl.
18. Install A/C compressor to engine mounting bolts.
- Torque: 25 Nm (18 ft. lbs.)
19. Install exhaust down pipes to catalytic converter.
20. Lower vehicle.
21. Connect EVAP purge solenoid and EVAP purge hose.
22. Connect fuel lines.
23. Connect brake assist vacuum hose.
24. Install cruise control and throttle cables.
25. Install battery tray and fuse block tray.
26. Install fuse block:
a. Install fuse block mounting bolts.
b. Route engine harness into fuse block.
c. Connect lower weather pack connector.
d. Connect main engine harness under fuse block panel.
e. Assemble fuse block and install fuse block cover.
27. Connect PCM electrical connector.
28. Install PCM boot to cowl.
29. Install cowl cover.
30. Connect following electrical connections:
a. main harness connector by master cylinder
b. rear H20 sensor
c. purge solenoid electrical
31. Connect purge hose to throttle body.
32. Install air box.
33. Install air cleaner lid and inlet duct.
34. Install intake air temperature (IAT) electrical connection.
35. Connect main ground on left fender wall.
36. Connect main wire feed to fuse block.
37. Install battery.
38. Add coolant.
39. Add power steering fluid.
40. Start engine and check for leaks.