Engine Replacement - Manual Transmission
Engine Replacement (Manual Transmission)^ Tools Required
- J 43628 Frame Alignment Fixture
- J 44015 Steering Linkage Installer
Removal Procedure
1. Remove the steering gear-to-intermediate shaft pinch bolt. Access is from the inside of the vehicle at the front of the dash.
2. Remove the battery.
3. Disconnect the main wire feed to the fuse block.
4. Disconnect the main ground on the left fender well.
5. Remove the Intake Air Temperature (IAT) electrical connector.
6. Remove the air cleaner lid and the inlet duct.
7. Remove the air box.
8. Disconnect the purge hose from the throttle body and route away from the engine.
9. Disconnect the following electrical connections:
9.1. The purge solenoid
9.2. The rear HO2S sensor
9.3. The main harness connector by the master cylinder
9.4. The transaxle back-up switch
10. Remove the front-of-dash cover.
11. Remove the PCM boot from the front of the dash.
12. Disconnect the PCM electrical connectors and secure to the engine.
13. Remove the fuse block.
14. Disconnect the engine harness main connector from the bottom of the fuse block.
15. Remove the battery tray and the fuse block tray.
16. Remove the cruise control and throttle cables.
17. Disconnect the brake assist vacuum line from the throttle body and route away from the engine.
18. Loosen the pinch bolt securing the control assembly rod to the control shaft lever assembly.
Notice: The control shaft lever retaining pin has a spring loaded locking feature securing the pin in place. If this spring is not depressed before attempting to remove the pin, damage to the pin will result.
19. Remove the pin retaining control shaft lever to shift control shaft of the transaxle.
20. Remove the retaining clips holding the control shaft lever assembly to the transaxle and frame assembly brackets.
21. Remove the control shaft lever assembly by pulling straight up from the pivot pins.
22. Drain the coolant.
23. Remove the heater hoses from the front of the dash.
24. Remove the upper and lower radiator hoses from the radiator.
25. Relieve the fuel pressure.
26. Disconnect the fuel lines.
27. Secure the radiator to the upper radiator support.
Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.
28. Raise the vehicle on a hoist.
29. Remove both of the front wheels.
30. Remove the right front splash shield.
31. Remove the left front wheel liner push pin from the frame.
32. Install wood blocks between the transaxle case and frame.
33. Install wood blocks between the crank pulley and frame.
34. Lower the vehicle.
35. Disconnect the right engine and left transaxle mounts by removing the mount assembly-to-engine/transaxle bolts. The mount brackets will remain on the engine and transaxle.
36. Disconnect the rear oxygen sensor harness from the frame at the 2 attachment points.
37. Remove the exhaust manifold pipe from the catalytic converter forward.
38. Remove the A/C line to frame attachment clip at the front of the frame.
Important: It is not necessary to disconnect the A/C lines.
39. Remove the A/C compressor from the engine and secure to the cooling module.
40. Remove the tie rod-to-steering knuckle bolts and separate the tie rod from the steering knuckle assembly. Discard the tie rod bolts.
41. Remove the stabilizer bar links from the strut assembly.
Notice: Do not attempt to separate the joint using a wedge-type tool because seal may be damaged.
42. Remove the lower ball stud bolt and separate the ball from the steering knuckle assembly.
43. Remove the suspension support assemblies.
44. Remove the suspension support cage nuts from the body. Discard the cage nuts.
45. Support the powertrain and frame with the powertrain lifting table and the J 43628.
46. Remove the remaining 4 frame-to-body attachment fasteners.
47. Carefully lower the powertrain and frame assembly from the vehicle.
48. Remove the remaining 4 cage nuts and discard.
Installation Procedure
1. Install the new cage nuts into the body as torque retention of the old nuts may not be sufficient.
Important: Ensure that the J 43628 fully engages into all alignment holes.
2. Carefully raise the powertrain into the vehicle.
Important: Do not tighten the fasteners at this time.
3. Install the 4 new frame-to-body bolts.
4. Install the suspension supports using the new bolt and tighten all of the frame bolts.
^ Tighten the suspension support bolts to 100 Nm (74 ft. lbs.).
5. Install the ball stud into the steering knuckle. Use the new ball stud nut.
^ Tighten the ball stud-to-steering knuckle nuts to 100 Nm (74 ft. lbs.).
6. Install the stabilizer link-to-strut assembly.
^ Tighten the stabilizer link-to-strut assembly to 65 Nm (50 ft. lbs.).
Important: Use a new tie rod nut. The torque retention of the old nut may not be sufficient.
7. Install the tie rod into the steering knuckle.
8. Using the J 44015, or equivalent, seat the tie rod end into the knuckle and tighten again.
^ Tighten the tie rod end linkage installer to 45 Nm (35 ft. lbs.).
9. Remove the linkage installer and install the new tie rod nut and tighten.
^ Tighten the tie rod nut to 60 Nm (45 ft. lbs.).
10. Install the exhaust manifold pipe.
11. Install the A/C compressor-to-engine mounting bolts.
^ Tighten the A/C compressor-to-block bolt to 25 Nm (18 ft. lbs.).
12. Install the A/C line-to-frame attachment clip at the front of the frame.
13. Route the rear oxygen sensor harness and attach to the attachment points.
14. Install the right engine mount bolts and install the left transaxle mount bolts.
^ Tighten the engine mount-to-engine mount bracket bolts to 55 Nm (41 ft. lbs.).
^ Tighten the transaxle mount bolts to 55 Nm (41 ft. lbs.).
Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.
15. Raise the vehicle.
16. Remove the wood blocks from the crank pulley and transaxle case.
17. Install the left front wheel liner push pin from the frame.
18. Install the right front splash shield.
19. Install both of the front wheels.
20. Lower the vehicle.
21. Remove the radiator from the upper radiator support.
22. Connect the fuel lines. Use new fuel line retainer clips.
23. Install the upper and lower radiator hoses from the radiator.
24. Install the heater hose.
25. Connect the brake assist vacuum lines to the brake booster.
26. Install and adjust the shift control rod as follows:
26.1. Install the shift rod into the shift linkage assembly.
26.2. Rotate the transaxle shift control shaft clockwise, toward the passenger side of the vehicle, and depress the spring loaded transaxle shift linkage lock pin on the transaxle case.
26.3. Pull up the shift lever boot.
26.4. Move the shift lever to 5th (reverse gate) using a 3/8 in. punch to hold in place.
26.5. Tighten the pinch bolt.
^ Tighten the shift control rod pinch bolt to 12 Nm (9 ft. lbs.) plus 180°.
27. Attach the cruise control and throttle cables.
28. Install the battery tray and fuse block tray.
29. Connect the engine harness main connector on the bottom of the fuse block.
30. Install the fuse block.
31. Connect the PCM electrical connectors.
32. Install the PCM boot under the front-of-dash cover.
33. Install the front-of-dash cover.
34. Connect the following connections:
^ The purge solenoid
^ The rear oxygen sensor
^ The main harness connector by the master cylinder
^ The transaxle back-up switch
35. Connect the purge hose to the throttle body.
36. Install the air cleaner box.
37. Install the air cleaner lid and the inlet duct.
38. Connect the Intake Air Temperature (IAT) electrical connection.
39. Connect the main ground on the left fender well.
40. Connect the main wire feed to the fuse block.
41. Install the battery.
42. Connect the steering gear-to-intermediate shaft pinch bolt and tighten.
^ Tighten the steering gear-to-intermediate shaft pinch bolt to 30 Nm (22 ft. lbs.).
43. Refill the coolant tank.
44. Add power steering fluid.