Engine Replacement

Engine Replacement


Tools Required
* J 36854 Heavy Duty Automotive Engine Stand
* J 36660-A Torque Angle Meter



Removal Procedure

Caution: Refer to Battery Disconnect Caution (Battery Disconnect Caution).
1. Disconnect the negative battery cable.
2. From inside the vehicle, disconnect the 2 engine control module (ECM) connectors.
3. Disconnect the 2 cowl wire electrical connectors from the connector mounting bracket.
4. Pull the engine harness wire from the passenger compartment.




5. Remove the 2 engine cover fasteners.
6. Remove the 2 engine cover plastic retainers.
7. Remove the engine cover (1) from the engine.
8. Relieve the fuel pressure. Refer to Fuel Pressure Relief (Fuel Pressure Relief).
9. Drain the cooling system. Refer to Cooling System Draining and Filling (Service and Repair).
10. Drain the engine oil.
11. Remove the serpentine drive belt. Refer to Drive Belt Replacement (Service and Repair).
12. If vehicle is equipped with A/C, remove the A/C compressor bolts and set A/C compressor aside. Refer to Compressor Replacement (Service and Repair).
13. If vehicle is equipped with a manual transmission, remove the following components:

* The crankshaft pulley-Refer to Crankshaft Pulley Replacement (Service and Repair).
* The drive belt tensioner-Refer to Drive Belt Tensioner Replacement (Service and Repair).





14. Remove the accelerator cable from the throttle body (1).
15. Remove the accelerator cable bracket from the throttle body.
16. Disconnect the intake air temperature (IAT) sensor.
17. Remove the air cleaner hose and cap assembly as follows:

* Disconnect the mass air flow (MAF) sensor connector.
* Disconnect 3 vacuum hoses from the air cleaner.
* Disconnect the air intake hoses from the throttle body.
* Unclip and remove the air cleaner cap.

18. Remove the air filter.
19. Disconnect the wire harness retaining clip from the air cleaner lower case.
20. Remove the following items from the air cleaner case:

* The one bolt
* The vacuum switching valve (VSV) bracket





21. Remove the following items:

* The 3 bolts
* The air cleaner lower box (3)

22. Disconnect the cruise control actuator electrical connector.
23. Remove the fuel line hose clamp.
24. Disconnect the fuel hose from the fuel line. Refer to Fuel Injection Fuel Rail Assembly Replacement (Service and Repair).
25. Disconnect the heater hose from the water by-pass pipe.
26. Disconnect the heater hose from the water hose union on the cylinder head.
27. Disconnect the brake booster vacuum hose from the brake booster.
28. Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (Service and Repair).
29. Remove the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (Service and Repair).
30. Remove the generator. Refer to Generator Replacement (Generator Replacement).
31. Remove the radiator. Refer to Radiator Replacement (Service and Repair).
32. Remove the engine relay box cover.




33. Disconnect the 3 engine compartment relay box connectors (1, 2, 3).




34. Disconnect 2 ground cables (1, 2) from front left side of engine compartment.




35. Disconnect the 2 wire harness clamps.
36. If equipped with manual transaxle, disconnect the clutch actuator cylinder. Refer to Clutch Actuator Cylinder Replacement (Service and Repair).




37. Disconnect the transaxle control cables from the transaxle.

1. Unclip the cable (1) from the mounting bracket.
2. Disconnect the transaxle control cables (2) from the transaxle.





38. If equipped with automatic transaxle, remove the shift cable from the transaxle.

1. Unclip the cable from the mounting bracket.
2. Remove the shift cable nut.





39. Unclip the wire harness (1), then remove the shift cable mounting bracket bolt (2).
40. Disconnect the oil cooler hoses.
41. On all models, remove the front drive axle. Refer to Front Wheel Drive Shaft Replacement (Service and Repair).
42. Raise and properly support the vehicle. Refer to Lifting and Jacking the Vehicle (Service Intervals).
43. Remove the right engine splash shield. Refer to Engine Splash Shield Replacement - Right Side (Engine Splash Shield Replacement - Right Side).
44. Remove left engine splash shield. Refer to Engine Splash Shield Replacement - Left Side (Engine Splash Shield Replacement - Left Side).




45. Place a drain pan, then disconnect the power steering lines (1) and drain the power steering system.
46. Remove the front exhaust pipe. Refer to Front Pipe Replacement (Service and Repair).
47. Disconnect the steering intermediate shaft assembly from under the dash panel. Refer to Intermediate Steering Shaft Replacement (FWD) (Intermediate Steering Shaft Replacement (FWD)).
48. Remove the right and left side driveshaft locknut.
49. Separate the left and right side tie rod end.
50. Disconnect the front stabilizer link assembly from the strut.
51. Remove 3 lower ball joint-to-control arm assembly nuts. Refer to Lower Control Arm Ball Joint Replacement (Service and Repair).




52. Set the engine lift, then remove the left side mounting insulator bolt and nut.




53. Remove the one bolt and 2 nuts from the right side engine mount.




54. Remove the 6 crossmember bolts.
55. Lower the engine and transaxle assembly.



Installation Procedure

1. Raise the engine and transaxle assembly.




2. Temporarily install the 6 crossmember bolts.





Notice: Refer to Fastener Notice (Fastener Notice).

3. Install the left side mounting insulator bolt and nut.

Tighten the left side mounting insulator nut and bolt 80 N.m (60 lb ft).





4. Install the 5 bolts and 2 nuts from the right side engine mount, then remove the engine lift.

Tighten the right side engine mount nuts and bolts to 52 N.m (38 lb ft).





5. Align the right side of the crossmember, then install and temporarily tighten bolt (1), then bolt (2).




6. Align the left side of the crossmember, then install and temporarily tighten bolt (1), then bolt (2).

* Tighten the right and left side bolts (1) to 157 N.m (116 lb ft).
* Tighten the right and left side bolts (2) to 113 N.m (83 lb ft).






7. Install the crossmember rear bolts and tighten.

Tighten the crossmember rear bolts to 39 N.m (29 lb ft).

8. Connect the lower control arm assembly.

Tighten the nuts and the bolt to 89 N.m (65.6 lb ft).

9. Connect the front stabilizer link assembly.

Tighten the nut to 74 N.m (54.6 lb ft).

10. Install the left side tie rod end.

Tighten the outer tie rod nut to 49 N.m (36.1 lb ft). Align the cotter pin slot by tightening the outer tie rod nut up to 1/6 additional turn, or 70 N.m (52 lb ft) maximum. Do not loosen the nut in order to insert the cotter pin.

11. Install the drive shaft lock nut.

Tighten the nut to 216 N.m (159 lb ft).

12. Install the front exhaust pipe. Refer to Front Pipe Replacement (Service and Repair).




13. Connect the power steering lines (1), then refill the power steering system. Refer to Checking and Adding Power Steering Fluid (Checking and Adding Power Steering Fluid).
14. Connect the oil cooler hoses.
15. Install the right and left engine splash shield. Refer to Engine Splash Shield Replacement - Left Side (Engine Splash Shield Replacement - Left Side) and Engine Splash Shield Replacement - Right Side (Engine Splash Shield Replacement - Right Side).
16. Lower the vehicle.
17. Install the steering intermediate shaft assembly. Refer to Intermediate Steering Shaft Replacement (FWD) (Intermediate Steering Shaft Replacement (FWD)).




18. Install the shift cable mounting bracket bolt (2) and clip the wire harness (1).

Tighten the bolt to 12 N.m (9 lb ft).





19. If equipped with an automatic transaxle, install the shift cable to the transaxle.

1. Install the shift cable nut.

Tighten the nut to 12 N.m (9 lb ft).

2. Clip the cable to the mounting bracket.

20. Pull the engine harness wire through the passenger compartment.
21. Connect the 3 cowl wire electrical connectors to the connector mounting bracket.
22. Connect the 2 ECM connectors.
23. Connect the ground cable to the engine.
24. Connect the ground cables to the transaxle.




25. If equipped with a manual transaxle, connect the transaxle control cables to the transaxle.

1. Connect the transaxle control cables (2) to the transaxle.
2. Clip the cable (1) to the mounting bracket.

26. Connect the clutch actuator cylinder. Refer to Clutch Actuator Cylinder Replacement (Service and Repair).




27. Connect the 3 engine compartment relay box connectors (1, 2, 3).




28. Connect 2 ground cables (1, 2) from front left side of engine compartment.

Tighten the bolts to 9 N.m (7 lb ft).





29. Connect the 2 wire harness clamps.
30. Install the engine relay box cover.
31. Install the radiator. Refer to Radiator Replacement (Service and Repair).
32. Install the generator. Refer to Generator Replacement (Generator Replacement).
33. Install the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (Service and Repair).
34. Install the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (Service and Repair).
35. Connect the brake booster vacuum hose to the brake booster.
36. Connect the heater hose to the water hose union on the cylinder head.
37. Connect the heater hose to the water by-pass pipe.
38. Connect the fuel tube to the fuel pipe.
39. Install the fuel tube clamp.
40. Connect the cruise control actuator electrical connector.




41. Install the air cleaner case as follows:

1. Install the air cleaner, then the 3 air cleaner case bolts (2).

Tighten the bolts to 7 N.m (62 lb in).

2. Connect the air cleaner wire harness clamp, connector, and hose.
3. Install the air filter.

42. Install the air cleaner cover as follows:

1. Install the air cleaner cap and air cleaner hose assembly.
2. Connect the air cleaner hose to the throttle body, then tighten the air cleaner hose clamp bolt.
3. Connect the air cleaner cap to the air cleaner case, then latch the 2 air cleaner clamps.
4. Connect the MAF sensor connector.

43. Connect the IAT sensor.




44. Connect the accelerator cable to the throttle body (1).
45. Install the accelerator cable to the accelerator cable bracket.
46. If the vehicle is equipped with a manual transmission, remove the following components:

* The drive belt tensioner-Refer to Drive Belt Tensioner Replacement (Service and Repair).
* The crankshaft pulley-Refer to Crankshaft Pulley Replacement (Service and Repair).

47. If the vehicle is equipped with A/C, position the A/C compressor and install the A/C compressor bolts. Refer to Compressor Replacement (Service and Repair).
48. Install the serpentine drive belt. Refer to Drive Belt Replacement (Service and Repair).
49. Refill the engine oil.
50. Refill the cooling system. Refer to Cooling System Draining and Filling (Service and Repair).
51. Connect the negative battery cable.




52. Position the engine cover (1) to the engine.
53. Install the 2 engine cover plastic retainers.
54. Install the 2 engine cover fasteners.
55. Start the engine and check for fluid leaks.