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.
3. Remove the air outlet duct.





4. Secure the cooling module to the upper body structure.
5. Relieve the fuel system pressure.





6. Disconnect the fuel line from the fuel rail.
7. Remove the supercharger.
8. Drain the cooling system.
9. Remove the radiator inlet hose.
10. Remove the surge tank to cylinder head pipe.
11. Remove the radiator outlet hose.





12. Remove the inlet (1) and outlet (2) heater hoses.





13. Disconnect these harness connectors:
^ TMAP sensor
^ Electronic temperature control (ETC)
^ Manifold absolute pressure (MAP) sensor
^ Barometric pressure (BARO) sensor
^ Crankshaft sensor
^ Oil pressure sensor
^ Purge solenoid
^ Ignition coil modules
^ Oxygen (O2) sensor
^ Vehicle speed sensor
^ Engine temperature sensor
^ Boost solenoid
^ Back up lamp switch
14. Remove the engine drive belt.
15. Disconnect the intercooler hoses.
16. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
17. Recover the refrigerant.





18. Disconnect the compressor and condenser hose assembly from the compressor.
19. Remove the AC compressor bolts and set the compressor aside.





20. Disconnect the starter harness connectors (3, 4, 5).
21. Disconnect the generator harness connectors.
22. Drain the engine oil.
23. Disconnect the front exhaust pipe from the exhaust manifold.
24. Disconnect the transmission shift cable from the transmission.
25. Use blocks of wood to support the powertrain assembly between the frame and the powertrain.
26. Remove the engine mount.





27. Remove the left transmission mount.





28. Disconnect the stabilizer links from the stabilizer bar.





29. Disconnect the outer tie rod ends from the steering knuckles.





30. Important: In order to prevent possible restraint system deployment, do not attempt to rotate the steering shaft.

Disconnect the intermediate shaft from the steering gear.





31. Disconnect the lower control arms from the steering knuckles.





32. Disconnect the drive axles from the steering knuckle.
33. Use a paint pen or magic marker in order to mark the frame to body position.





34. Lower the vehicle to about 3 feet off the ground in order to position the lift table under the frame.
35. Use wood blocks as necessary between the lift table and the frame to support the assembly.
36. Slowly remove the frame bolts using this sequence:
1. Remove the front frame bolts.
2. Partially unscrew the rear frame bolts until 1.5 inches of bolt shank is exposed.
37. Slowly lower the table to the floor.
38. Attach the engine lift hoist to the engine lift hooks.





39. Remove the starter.
40. Remove the transmission to engine bolts.
41. Separate the engine from the transmission.
42. Remove the clutch pressure plate and disk.
43. Remove these components:
^ Exhaust manifold
^ Exhaust manifold studs
^ Engine mount bracket
^ Fuel rail
^ Thermostat housing and feed pipe
^ Generator
44. Remove the engine from the engine lift.

Installation Procedure
1. Attach the engine lift hoist to the engine lift hooks.
2. Install these components:
^ Exhaust manifold
^ Engine mount bracket.
^ Fuel rail
^ Idler pulley
^ Drive belt tensioner
^ Thermostat housing and feed pipe
^ Generator
^ Flywheel
^ Clutch pressure plate and disk
^ AC Compressor
3. Align the engine to the transmission.





4. Notice: Refer to Fastener Notice in Service Precautions.

Secure the engine to the transmission.
^ Tighten the transmission to engine bolts to 75 Nm (55 ft. lbs.).





5. Install the starter.
6. Remove the engine lift from the engine.





7. Raise and position the frame and powertrain assembly to the vehicle.
8. Hand start all the frame bolts while aligning the frame to the paint marks.
9. Tighten the frame bolts.
^ Tighten the frame bolts to 100 Nm (74 ft. lbs.) plus 180 degrees.
10. Remove the lift table.





11. Connect the drive axles to the steering knuckles.





12. Connect the lower control arm to the steering knuckle.





13. Connect the intermediate steering shaft to the steering gear.





14. Connect the outer tie rod ends to the steering knuckles.





15. Connect the stabilizer links to the stabilizer bar.





16. Install the left transmission mount.





17. Install the engine mount.
18. Remove the wood blocks between the powertrain and frame.
19. Connect the transmission shift cable to the transmission.





20. Connect the exhaust take down pipe to the exhaust manifold.
^ Tighten the nuts to 30 Nm (22 ft. lbs.).
21. Connect the generator harness connectors.
^ Tighten the generator terminal nut to 20 Nm (15 ft. lbs.).





22. Connect the starter harness connectors (3, 4, 5).
^ Tighten the battery terminal nut to 17 Nm (13 ft. lbs.).
^ Tighten the S-terminal nut to 3 Nm (27 inch lbs.).
23. Install the compressor and condenser hose assembly to the compressor.
24. Evacuate and charge the refrigerant system.
25. Install the supercharger.
26. Install the engine drive belt.
27. Connect the intercooler hoses.
28. Connect these harness connectors:
^ TMAP sensor
^ ETC
^ MAP sensor
^ Crankshaft sensor
^ Oil pressure sensor
^ Purge solenoid
^ BARO sensor
^ Ignition coil modules
^ O2 sensor
^ Vehicle speed sensor
^ Engine temperature sensor
^ Boost solenoid





29. Install the inlet heater hose (1) and outlet heater hose (2).
30. Install the radiator outlet hose.





31. Connect the fuel line to the fuel rail.
32. Install the surge tank to the cylinder head pipe.
^ Tighten the bolt to 10 Nm (89 inch lbs.).





33. Release the cooling module from the upper body structure.
34. Install the air outlet duct.
35. Connect the negative battery cable.
36. Fill the engine with engine oil to the proper level.
37. Fill the cooling system.
38. Road test the vehicle.