With Manual Transmission

Engine Replacement (w/Manual Transmission)


Tools Required
* J 42451-1 Engine Support Adapter
* J 45059 Angle Meter



Removal Procedure





1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair) .
2. Remove the hood. Refer to Hood Replacement (Service and Repair) .
3. Recover the air conditioning (A/C) system. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging) .
4. Remove the drive belt. Refer to Drive Belt Replacement (With A/C) (Drive Belt Replacement (With A/C))Drive Belt Replacement (Without A/C) (Drive Belt Replacement (Without A/C)) .
5. Remove the radiator. Refer to Radiator Replacement (Service and Repair) .
6. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) (Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (With CH 48027-100) (Fuel Pressure Relief (With CH 48027-100))Fuel Pressure Relief (Without CH 48027) (Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (Without CH 48027-100) (Fuel Pressure Relief (Without CH 48027-100)) .
7. Disconnect the evaporative emission (EVAP) canister purge solenoid tube from the valve (1). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service) .
8. Disconnect the fuel feed pipe (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service) .
9. Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement (SKY) (Service and Repair)Air Inlet Grille Panel Replacement (Solstice) (Service and Repair) .
10. Remove the transmission. Refer to Transmission Replacement (With Z0K) (Transmission Replacement (With Z0K))Transmission Replacement (Without Z0K) (Transmission Replacement (Without Z0K)) .
11. After the transmission is removed, reinstall the bolt from the differential case bracket assembly to body, in order to remove the support from under the rear drive module.




12. Reposition the radiator inlet hose clamp at the engine.
13. Remove the radiator inlet hose.




14. If the vehicle is equipped with a engine oil cooler perform the following steps, otherwise proceed to step 23.
15. Reposition the radiator outlet hose clamps at the thermostat housing and oil cooler.
16. Remove the radiator outlet hose from the thermostat housing and oil cooler.
17. Reposition the outlet hose out of the way.




18. Reposition the surge tank outlet hose clamps at the thermostat housing and oil cooler.
19. Remove the surge tank outlet hose from the thermostat housing and oil cooler.




20. Reposition the surge tank outlet hose clamp at the surge tank.
21. Remove the surge tank clip from the oil level indicator tube bracket.
22. Remove the surge tank outlet hose. Proceed to step 26.




23. If the vehicle is not equipped with a engine oil cooler, reposition the radiator outlet hose clamp at the thermostat housing.
24. Remove the radiator outlet hose from the thermostat housing.
25. Remove the radiator outlet hose clip (1) from the outlet hose bracket.




26. Reposition the surge tank air bleed hose clamp at the engine.
27. Remove the surge tank air bleed hose (1) from the engine.
28. Reposition the air bleed hose (2) out of the way.




29. Reposition the heater inlet and outlet hose clamps at the thermostat housing.
30. Remove the heater inlet (2) and outlet (1) hoses from the thermostat housing.
31. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair) .
32. Drain the engine oil.




33. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor.
34. Disconnect the engine wiring harness electrical connector (2) from the oil pressure sensor.
35. Lower the vehicle.
36. Remove the positive battery cable clip (7) from the bracket.
37. Cut the engine harness tie straps.




38. Remove the negative battery cable ground bolt.
39. Remove the negative battery cable ground terminal and engine harness ground terminal from the cylinder head.




40. Disconnect the engine wiring harness electrical connector (1) from the generator.
41. Reposition the positive battery cable terminal boot (4).
42. Remove the generator terminal nut (2).
43. Remove the positive battery cable terminal from the generator (5).
44. Disconnect the engine wiring harness electrical connector (6) from the A/C compressor.
45. Reposition the negative/positive battery cable.




46. Disconnect the engine wiring harness electrical connector from the A/C refrigerant pressure sensor.




47. Disconnect the engine wiring harness electrical connector from the windshield wiper motor.
48. Remove the engine harness clip from the wiper motor hole.




49. Remove the engine harness clip from the surge tank air bleed hose.




50. Disconnect the engine wiring harness electrical connector (1) from the intake camshaft position (CMP) actuator.
51. Disconnect the engine wiring harness electrical connector (2) from the exhaust CMP actuator.




52. Remove the engine harness clip (1) from the camshaft cover.




53. Disconnect the engine wiring harness electrical connectors from the ignition coils.




54. Remove the connector position assurance (CPA) retainers from the heated oxygen sensor (HO2S) electrical connectors.
55. Disconnect the engine wiring harness electrical connector (1) from the front HO2S.
56. Disconnect the engine wiring harness electrical connector (2) from the rear HO2S.
57. Disconnect the engine harness clips (1) from the junction block bracket.
58. Disconnect the HO2S electrical connector clip (4) from the strut.




59. Disconnect the engine wiring harness electrical connector from the intake CMP sensor.




60. Disconnect the engine wiring harness electrical connector from the exhaust CMP sensor.
61. Remove the engine harness ground terminal bolt (1) and reposition the engine harness ground terminal (2).
62. Disconnect the engine wiring harness electrical connector (6) from the engine coolant temperature (ECT) sensor.




63. Disconnect the engine wiring harness electrical connector (1) from the EVAP canister purge solenoid.
64. Disconnect the engine harness clip (2) from the EVAP canister purge solenoid valve bracket.
65. Disconnect the engine harness clips (3, 4) from the camshaft cover.
66. Remove the EVAP canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement (Service and Repair) .




67. Remove the engine harness bracket (1) from the intake manifold cover stud.
68. Disconnect the engine harness clip (2) from the bracket.




69. Remove the intake manifold cover bracket bolts and bracket.
70. Gather all branches of the engine harness and lay off to the side.




71. Remove the A/C compressor line bolt and reposition the line off to the side.
72. Raise and support the vehicle.




73. Remove the power steering pump bracket bolts and reposition the pump and bracket off to the side.
74. Lower the vehicle.




75. Remove the left engine mount upper nut.




76. Remove the right engine mount upper nut.
77. Install the J 42451-1 to the engine.
78. Install a suitable engine lifting devise to the engine.
79. Remove the engine from the vehicle.
80. Remove the clutch pressure plate and disc. Refer to Clutch Drive Plate and Clutch Driven Plate (Service and Repair) .




81. Remove the flywheel bolts and flywheel.
82. Install the engine to an engine stand.




83. Remove the A/C compressor bolt and compressor.




84. Remove the catalytic converter to bracket bolt.




85. Remove the catalytic converter nuts (1).
86. Remove the catalytic converter gasket (2) and converter from the engine.



Installation Procedure





1. Install the catalytic converter gasket (2) and converter to the engine.

Notice: Refer to Fastener Notice (Fastener Notice) .

2. Install the catalytic converter nuts (1).

Tighten the nuts to 25 N.m (18 lb ft).





3. Install the catalytic converter to bracket bolt.

Tighten the bolt to 25 N.m (18 lb ft).





4. Install the A/C compressor and bolts.

Tighten the bolts in the sequence shown to 22 N.m (16 lb ft).





5. Install a suitable engine lifting devise to the engine.
6. Remove the engine from the stand.
7. Using a nylon bristle brush clean the thread adhesive from the flywheel bolt holes, if necessary.
8. Install the flywheel and bolts.

Tighten the bolts to 53 N.m (39 lb ft) plus an additional 25 degrees using the J 45059 .

9. Install the clutch pressure plate and disc. Refer to Clutch Drive Plate and Clutch Driven Plate (Service and Repair) .




10. Install the engine to the vehicle.
11. Install the right engine mount upper nut.

Tighten the nut to 50 N.m (37 lb ft).





12. Install the left engine mount upper nut.

Tighten the nut to 50 N.m (37 lb ft).

13. Remove the J 42451-1 from the engine.
14. Raise and support the vehicle.




15. Position the power steering pump and bracket to the engine and install the bracket bolts.

Tighten the bolts to 58 N.m (43 lb ft).

16. Lower the vehicle.




17. Position the A/C compressor line and install the bolt .

Tighten the bolt to 22 N.m (16 lb ft).





18. Install the intake manifold cover bracket and bolts.

Tighten the bolt to 25 N.m (18 lb ft).

19. Position the branches of the engine harness to the engine.




20. Connect the engine harness clip (2) to the bracket.
21. Install the engine harness bracket (1) to the intake manifold cover stud.
22. Install the EVAP canister purge solenoid valve. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement (Service and Repair) .




23. Connect the engine harness clips (3, 4) to the camshaft cover.
24. Connect the engine harness clip (2) to the EVAP canister purge solenoid valve bracket.
25. Connect the engine wiring harness electrical connector (1) to the EVAP canister purge solenoid.




26. Connect the engine wiring harness electrical connector (6) to the ECT sensor.
27. Position the engine wiring harness ground terminal (2) and install the bolt (1).

Tighten the bolt to 10 N.m (89 lb in).

28. Connect the engine wiring harness electrical connector to the exhaust CMP sensor.




29. Connect the engine wiring harness electrical connector to the intake CMP sensor.




30. Connect the HO2S electrical connector clip (4) to the strut.
31. Connect the engine harness clips (1) to the junction block bracket.
32. Connect the engine wiring harness electrical connector (2) to the rear HO2S.
33. Connect the engine wiring harness electrical connector (1) to the front HO2S.
34. Install the CPA retainers to the HO2S electrical connectors.




35. Connect the engine wiring harness electrical connectors to the ignition coils.




36. Install the engine harness clip (1) to the camshaft cover.




37. Connect the engine wiring harness electrical connector (2) to the exhaust CMP actuator.
38. Connect the engine wiring harness electrical connector (1) to the intake CMP actuator.




39. Install the engine harness clip to the surge tank air bleed hose.




40. Connect the engine wiring harness electrical connector to the windshield wiper motor.
41. Install the engine harness clip to the wiper motor hole.




42. Connect the engine wiring harness electrical connector to the A/C refrigerant pressure sensor.




43. Position the negative/positive battery cable.
44. Connect the engine wiring harness electrical connector (6) to the A/C compressor.
45. Install the positive battery cable terminal to the generator (5).
46. Install the generator terminal nut (2).

Tighten the nut to 20 N.m (15 lb ft).

47. Position the positive battery cable terminal boot (4).
48. Connect the engine wiring harness electrical connector (1) to the generator.




49. Position the engine harness ground terminal behind the negative battery cable terminal and position against the cylinder head.
50. Install the negative battery cable ground terminal bolt.

Tighten the bolt to 10 N.m (89 lb in).

51. Install NEW tie straps to the engine harness.
52. Install the positive battery cable clip (7) to the bracket.
53. Raise and support the vehicle.




54. Connect the engine wiring harness electrical connector (2) to the oil pressure sensor.
55. Connect the engine wiring harness electrical connector (1) to the CKP sensor.
56. Lower the vehicle.




57. Install the heater inlet (2) and outlet (1) hoses to the thermostat housing.
58. Position the heater inlet and outlet hose clamps at the thermostat housing.




59. Position the air bleed hose (2).
60. Install the surge tank air bleed hose (1) to the engine.
61. Position the surge tank air bleed hose clamp at the engine.




62. If the vehicle is not equipped with a engine oil cooler perform the following steps, otherwise proceed to step 66.
63. Install the radiator outlet hose to the thermostat housing.
64. Reposition the radiator outlet hose clamp at the thermostat housing.
65. Install the radiator outlet hose clip (1) to the outlet hose bracket. Proceed to step 71.




66. If the vehicle is equipped with a engine oil cooler, install the surge tank outlet hose.
67. Install the surge tank clip to the oil level indicator tube bracket.
68. Position the surge tank outlet hose clamp at the surge tank.




69. Install the surge tank outlet hose to the thermostat housing and oil cooler.
70. Position the surge tank outlet hose clamps at the thermostat housing and oil cooler.




71. Position the outlet hose.
72. Install the radiator outlet hose to the thermostat housing and oil cooler.
73. Position the radiator outlet hose clamps at the thermostat housing and oil cooler.




74. Install the radiator inlet hose.
75. Position the radiator inlet hose clamp at the engine.
76. Install the transmission. Refer to Transmission Replacement (With Z0K) (Transmission Replacement (With Z0K))Transmission Replacement (Without Z0K) (Transmission Replacement (Without Z0K)) .
77. Install the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement (SKY) (Service and Repair)Air Inlet Grille Panel Replacement (Solstice) (Service and Repair) .




78. Connect the fuel feed pipe (2) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service) .
79. Connect the EVAP canister purge solenoid tube to the valve (1). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service) .
80. Install the radiator. Refer to Radiator Replacement (Service and Repair) .
81. Install the drive belt. Refer to Drive Belt Replacement (With A/C) (Drive Belt Replacement (With A/C))Drive Belt Replacement (Without A/C) (Drive Belt Replacement (Without A/C)) .
82. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging) .
83. Install the hood. Refer to Hood Replacement (Service and Repair) .
84. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair) .
85. Fill the engine oil.