Engine Replacement

Engine Replacement

Removal Procedure

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Service and Repair).
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
3. Disconnect the fuel feed pipe quick connect fitting at the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
4. Disconnect the evaporative emission (EVAP) line quick connect fitting from the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
5. Remove the fuel feed pipe clip from the fuel line bracket.
6. Remove the transaxle shift cable clip from the fuel line bracket.
7. Remove the battery tray. Refer to Battery Tray Replacement (Service and Repair).
8. Remove the vacuum brake booster hose from the intake manifold.
9. Remove the coolant recovery inlet pipe clip from the fuel rail.
10. Remove the coolant recovery inlet hose from the cylinder head.
11. Remove the radiator inlet hose from the cylinder head.
12. Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (LAF) (Radiator Outlet Hose Replacement)Radiator Outlet Hose Replacement (LDK or LHU) (Radiator Outlet Hose Replacement).




13. Remove the heater inlet hose (2) from the thermostat housing.
14. Remove the coolant recovery reservoir/heater inlet hose (4) from the thermostat housing.
15. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
16. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement (LAF) (Service and Repair).
17. Disconnect the engine wiring harness electrical connector from the air conditioning (A/C) compressor.




18. Unbolt the A/C compressor and reposition out of the way.
19. Remove the positive battery cable from the starter motor.
20. Disconnect the generator electrical connectors.
21. Lower the vehicle.




22. Remove the transaxle shift cable from the range select lever.
23. Release the shift control cable retaining clip and remove the cable from the shift control cable bracket.





Note: The radiator/condenser/fan assembly will stay in the vehicle during engine removal.

24. Using long tie straps, secure the radiator/condenser/fan assembly to the radiator support.
25. Raise the vehicle.
26. Remove the front wheels and tires. Refer to Tire and Wheel Removal and Installation (Service and Repair).
27. Remove the front wheelhouse panel..
28. Drain the transaxle fluid.
29. Remove the fluid cooler lines at the transmission. Refer to Fluid Cooler Inlet Hose Replacement (Fluid Cooler Inlet Hose Replacement) and Fluid Cooler Outlet Hose Replacement (Fluid Cooler Outlet Hose Replacement).
30. Remove the catalytic converter..





Note: Secure the steering wheel in the straight forward position before separating the intermediate shaft from the steering gear, or damage to the SIR coil will occur.

31. Remove the intermediate to steering gear pinch bolt and disconnect the intermediate shaft from the steering gear. Discard the pinch bolt.
32. Separate the tie rods from the steering knuckles..
33. Remove the wheel drive shafts..
34. Lower the vehicle.




35. Remove the engine mount to bracket bolts (1).




36. Remove the transaxle mount to transaxle bolts.
37. Raise the vehicle.





Note: During the powertrain removal support the vehicle body by placing a jack at the rear of the vehicle.

38. Position a engine support table under the powertrain assembly.

Note: Blocks of wood can be used between the front of the frame and the oil pan to table in order to level the powertrain during the removal.

39. With the table positioned, fully raise the table to contact the powertrain assembly.
40. Remove the frame to body bolts. Discard the bolts.

Note: When lowering the engine/transaxle assembly, verify all brake lines, shifter cables and other components are free during removal.

41. Lower the engine table and raise the body on the hoist until the engine/transaxle and frame are free from the vehicle.
42. Disconnect the engine wiring harness electrical connectors as necessary.




43. Remove the starter motor bolts and starter.




44. Remove the torque converter to flexplate bolts (1).
45. Install a suitable lifting device to the engine.




46. Remove the transaxle bolts from the engine.
47. Separate the engine from the transaxle.
48. Install the engine to a suitable engine stand.

Installation Procedure




1. Install a suitable lifting device to the engine.
2. Using the lifting device, position and install the engine to the transaxle.

Caution: Refer to Fastener Caution (Fastener Caution).

3. Install the transaxle bolts to the engine and tighten to 75 Nm (55 lb ft).




4. Install the torque converter to flexplate bolts (1) and tighten to 60 Nm (44 lb ft).
5. Remove the engine lifting device.




6. Install the starter motor and bolts and tighten to 53 Nm (39 lb ft).
7. Connect the engine wiring harness electrical connectors as necessary.




8. Position the powertrain and support table under the vehicle.
9. Raise the powertrain into position under the vehicle.
10. With the table positioned, if required, lower the vehicle over the powertrain.
11. Align the lower radiator pins with the frame. Ensure all hoses and electrical harnesses are correctly routed and free from the loading path of the powertrain.
12. Install the NEW frame to body bolts and tighten to 155 Nm (114 lb ft).
13. Lower the vehicle.




14. Install the transaxle mount to transaxle bolts and tighten to 55 Nm (41 lb ft).





Note: The engine mount to bracket bolts must be hand started. Do not pry the engine mount to align the holes.

15. Install the engine mount to bracket bolts (1) and tighten to 50 Nm (37 lb ft).
16. Raise and support the vehicle.
17. Install the wheel drive shafts.




18. Connect the outer tie rods to the steering knuckles.




19. Position the intermediate shaft to the steering gear and install a NEW pinch bolt and tighten to 34 Nm (25 lb ft).
20. Install the catalytic converter..
21. Install the fluid cooler lines at the transaxle. Refer to Fluid Cooler Inlet Hose Replacement (Fluid Cooler Inlet Hose Replacement) and Fluid Cooler Outlet Hose Replacement (Fluid Cooler Outlet Hose Replacement).
22. Install the front wheelhouse panel..
23. Install the front wheels and tires. Refer to Tire and Wheel Removal and Installation (Service and Repair).
24. Lower the vehicle.




25. Unsecure and position the radiator/condenser/fan assembly.




26. Install the shift control cable to the shift control cable bracket and engage the shift control cable retaining clip.
27. Install the transaxle shift cable to the range select lever.
28. Raise and support the vehicle.
29. Connect the generator electrical connectors.
30. Install the positive battery cable to the starter motor, tighten to 9 Nm (80 lb in)




31. Position the A/C compressor and install the bolts and tighten to 50 Nm (37 lb ft).
32. Connect the engine wiring harness electrical connector to the A/C compressor.
33. Lower the vehicle.
34. Install the coolant recovery reservoir/heater inlet hose to the thermostat housing.
35. Install the heater inlet hose to the thermostat housing.
36. Install the radiator inlet hose from the cylinder head.
37. Install the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (LAF) (Radiator Outlet Hose Replacement)Radiator Outlet Hose Replacement (LDK or LHU) (Radiator Outlet Hose Replacement).
38. Position and install the coolant recovery inlet hose to the cylinder head.
39. Install the coolant recovery inlet pipe clip to the fuel rail.
40. Position and install the vacuum brake booster hose to the intake manifold.
41. Install the battery tray. Refer to Battery Tray Replacement (Service and Repair).
42. Install the transaxle shift cable clip to the fuel line bracket.
43. Install the fuel feed pipe clip to the fuel line bracket.
44. Connect the EVAP line quick connect fitting to the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
45. Connect the fuel feed pipe quick connect fitting at the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
46. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
47. Fill the transaxle with fluid. Refer to Transmission Fluid Level and Condition Check (Transmission Fluid Level and Condition Check).
48. Refill the engine with oil. Refer to Engine Oil and Oil Filter Replacement (LAF) (Service and Repair).
49. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn (Testing and Inspection).
50. Start the engine and allow the engine to run, inspect for leaks. Correct as necessary.