D. CS (AWD and FWD) Engine Replacement

1. Install the # 2 connecting rod cap and finger start the connecting rod bolts.

2. Install the engine oil pan with four bolts and snug tight.

3. Lower the vehicle.

4. Remove engine trim cover.

5. Disconnect the chassis fuel line from the engine fuel rail.

6. Cap both open fuel lines.

7. Drain the engine coolant from the vehicle and save for reuse.

8. Disconnect the cruise control cable from the throttle body.

9. Remove the cruise control solenoid and vacuum reservoir.

10. Remove radiator shroud.

11. Remove radiator core support.

12. Remove radiator cooling fans.

13. Remove upper radiator hose.

14. Disconnect the air temp sensor located in the air cleaner box.





15. Remove the air cleaner box (Figure 39).

16. Remove the lower radiator hose.

17. Disconnect the throttle cables from the throttle body and intake manifold.

18. Disconnect all vacuum lines to the intake manifold.

19. Disconnect the transaxle multi-pin electrical connector.

20. Disconnect the transaxle output speed sensor.

21. Disconnect the transaxle range sensor.

22. Disconnect the transaxle solenoid packs.

23. Remove the transaxle electrical harness from the transaxle by prying loose the wire harness from the clip.

24. Discharge the air conditioning system using a suitable refrigerant recovery system.

25. Remove the engine wire harness ground at left inner frame rail.

26. Disconnect the transaxle selector shift cable.

27. Disconnect the transaxle oil cooler lines at the radiator.

28. Disconnect the block heater (if so equipped) 110 v power cord at the heater.

29. Disconnect the hose to the coolant recovery bottle.

30. Disconnect all heater hoses at the heater.

31. Disconnect the front brake lines. Use a brake pedal prop to prevent draining of the brake fluid from the brake reservoir.

32. Disconnect both air conditioning lines at the compressor and cap off the openings.

33. Disconnect the air conditioning clutch electrical connector.

34. Disconnect the electrical harness from the generator.

35. Disconnect the electrical harness from the duty cycle purge solenoid.

36. Disconnect the electrical harness from the starter.

37. Disconnect the engine harness from the chassis harness.

38. Disconnect the front oxygen sensor.

39. Raise the vehicle.

40. Remove both front wheel/tire assemblies.

41. Unfasten the front half of both right and left inner fender liners and roll the liners rearward.

42. Disconnect the harness from the PCM.

43. Disconnect the left wheel speed sensor connector and the speed sensor wire from the retainer.

44. Disconnect the left sway bar link at the left front strut (Figure 40).





45. Remove left axle hub nut (Figure 40).

46. Remove left steering knuckle to strut pinch bolts and separate (Figure 40).

47. Pull left knuckle outboard to separate it from the axle shaft.

48. Remove the ground cable from the transaxle housing.

49. Remove the left fascia screws.

50. Remove the right wheel speed sensor and retainer.

51. Remove the right sway bar link at the right front strut.

52. Remove the right axle hub nut.

53. Remove the right steering knuckle to strut pinch bolts and separate.

54. Separate the right axle from the right steering knuckle.

55. Remove the torque converter to drive plate bolts.

56. Separate the harness fastener of the mid-catalyst oxygen sensor from the cradle.

57. Disconnect the mid-catalyst oxygen sensor connector.

58. Remove the two exhaust pipe flange-to-exhaust manifold nuts.

59. Pry the heat shield tab off the exhaust manifold stud.

60. Separate the exhaust pipe from the engine and support the exhaust system.

61. Remove the vehicle center exhaust system hanger bolts.

62. Remove the vehicle rear exhaust system hanger bolts.

63. Remove the exhaust system from the vehicle.

64. Separate the brake lines from the brake line spacer isolator located on the left side of the engine compartment by the brake hydraulic control unit.

65. For AWD model:

a. Paint mark the propeller shaft to the rear differential at the PTU.

b. Separate the propeller shaft to the rear differential at the transaxle power transfer unit. Support the propeller shaft to the under body.

c. Remove engine/transaxle assembly support plate from the suspension cradle.

66. Remove steering coupling pin using tool # 6831A.

67. Remove both engine mount-to-suspension cradle nuts.

68. Paint mark the suspension cradle to the chassis.

69. Disconnect the crank position sensor.

70. Position the front (right and left) brake lines aside to clear the suspension cradle when it is dropped.

71. Place suspension cradle support fixture (essential tool # 8874) under the vehicle.

72. Lower the vehicle onto the suspension cradle support fixture.

73. Remove right engine support mount.

74. Remove all four suspension cradle-to-body bolts.

75. Raise the vehicle and slide the suspension cradle fixture out from under the vehicle.

NOTE:
The following steps will be performed with the engine and transaxle on the suspension cradle.

76. Remove the left axle shaft.

77. Remove the serpentine drive belt.

78. Remove the generator.

79. Remove the power steering reservoir.

80. Remove the power steering pump.

81. Remove the belt tensioner.

82. Remove the three idler pulleys.

83. Disconnect the IAC connector at the throttle body.

84. Disconnect the TPS connector at the throttle body.

85. Disconnect the intake manifold short runner actuation valve connector.

86. Disconnect the intake manifold long runner actuation valve connector.

87. Disconnect the MAP sensor located on the intake manifold.

88. Unfasten the wiring harness support bracket.

89. Remove the PVC hose.

90. Remove the PVC valve.

91. Remove crankshaft damper.

92. Remove EGR tube.

93. Remove oil fill tube.

94. Remove the two intake manifold support brackets.

95. Remove the intake manifold from the engine.

96. Disconnect the remaining components from the engine wire harness (knock sensor, fuel injectors, ignition coils, ignition noise suppression capacitors, EGR valve, cam position sensor, oil pressure sending unit, etc).

97. Remove the engine wire harness.

98. Remove right rear exhaust heat shield.

99. Remove exhaust cross over pipe.

100. Remove the front exhaust manifold and discard the exhaust manifold to engine gasket.

101. Remove the rear exhaust manifold and discard the exhaust manifold to engine gasket.

102. Remove the EGR valve and discard the EGR valve-to-cylinder head gasket.

103. Remove the ignition coil packs.

104. Remove the coolant hoses from the engine (oil cooler-to-engine, oil cooler-to-heater).

105. Remove the valve cover ground straps.

106. Remove the transaxle rear structural support bolt from the engine.

107. Remove the starter from the engine.

108. Remove the crankshaft position sensor.

109. Remove the air conditioning compressor.

110. Remove the air conditioning compressor mounting bracket.





111. For AWD models: Remove the PTU (Figure 41).

a. Remove the PTU/transaxle left upper bracket.

b. Remove the PTU heat shield.

c. Remove the PTU collar bolts from the oil pan.

d. Remove the PTU to transaxle bolts.

e. Separate the PTU from the transaxle.

112. Remove all engine-to-transaxle bell housing bolts.





113. Connect one end of the engine lifting bracket from special tool kit 8534 to the right rear of the cylinder head outer most bolt access hole with a bolt and tighten (Figure 42).

114. Install a bolt into the inner most bolt access hole next to the engine lift bracket to position the engine lift bracket (Figure 42).





115. Connect an engine hoisting chain to the left timing chain cover engine lift eye and to the engine lift bracket installed in Step 113 (Figure 43).

116. Lift the engine with a suitable hoist such that the front and rear engine mounts just lift off the suspension cradle.

117. Remove front engine mount.

118. Remove rear engine mount.

119. Carefully separate the engine from the transaxle.

120. Place the old engine in a suitable cradle to prevent the engine from tipping on its side.

121. Remove the drive plate and discard the bolts.

122. Remove the engine lifting chain and bracket.

123. Install the engine lifting chain and bracket onto the new engine by repeating Step 113 through Step 115.

124. Spread a light coating of universal suspension grease all around in the hole at the end of the crankshaft where the nose of the torque converter nests.

125. Install the drive plate with new bolts and tighten to 55 ft. lbs. (75 N.m).

126. Position and align the engine to the transaxle. Make sure the engine dowels are properly seated into the transaxle.

127. Install the upper four engine to transaxle bell housing bolts and tighten to 70 ft. lbs. (95 N.m).

128. Install the rear engine mount plate and tighten bolts to 40 ft. lbs. (54 N.m).

129. Install the rear engine mount upper nut and tighten to 75 ft. lbs. (101 N.m).

130. Install the rear engine mount bracket bolts and tighten to 40 ft. lbs. (54 N.m).

131. Install the rear engine mount to the engine mount bracket and tighten to 75 ft. lbs. (101 N.m).

132. Install the left motor mount to the engine block and tighten the bolts to 40 ft. lbs. (54 N.m).

133. Lower the engine into the suspension cradle and remove the engine lifting chain and bracket.

134. Install the remaining engine-to-transaxle bell housing bolts and tighten to 70 ft. lbs. (95 N.m).

135. For AWD models: Install PTU unit (Figure 41) as follows:

a. Align the PTU into the transaxle, install the upper bolts and tighten to 40 ft. lbs. (54 N.m).

b. Install the PTU to transaxle lower bolts and tighten to 21 ft. lbs. (28 N.m).

c. Install the PTU collar and brace bolts to the oil pan and tighten to 40 ft. lbs. (54 N.m).

d. Install the PTU heat shield and tighten bolts to 20 ft. lbs. (28 N.m).

e. Install the PTU/transaxle left bracket and tighten the bolts to 40 ft. lbs. (54 N.m).





136. Install the air conditioning mounting bracket and hand start the four bolts. Then tighten the bolts to 30 ft. lbs. (41 N.m) in the sequence as follows (Figure 44):

a. Tighten the upper rear bolt.

b. Tighten the upper front bolt.

c. Tighten the bottom rear bolt.

d. Tighten the bottom front bolt.

137. Install the air conditioning compressor. Snug the bolts at this time.

138. Install the crankshaft position sensor.

139. Install the starter, dust shield, spacer, and bracket. Tighten the bolts to 40 ft. lbs. (54 N.m).

140. Install the transaxle rear structural support bolt to the engine and tighten to 40 ft. lbs. (54 N.m).

141. Install the ground straps onto the front cylinder head cover and to the cylinder head.

142. Install the coolant hoses to the engine (oil cooler-to-engine and oil cooler-to-heater).

143. Install the ignition coil packs.

144. Remove the plug in the EGR passage at the rear of the right cylinder head (rear cylinder head).





145. Install the EGR valve with a new gasket to the left rear cylinder head (Figure 45). Tighten the bolts to 97 in. lbs. (11 N.m).

146. Install the rear exhaust manifold with new exhaust manifold gasket. Tighten the bolts to 200 in. lbs. (23 N.m).

CAUTION:
Do not over tighten.

147. Install the front exhaust manifold with new exhaust manifold gasket. Tighten the bolts to 200 in. lbs. (23 N.m).

CAUTION:
Do not over tighten.

148. Install the exhaust cross over pipe and tighten the nuts to 30 ft. lbs. (41 N.m).

149. Install the right rear exhaust heat shield and tighten to 98 in. lbs. (10 N.m).

150. Install engine wire harness onto the engine.

151. Connect the engine wire harness to the appropriate electrical components (knock sensor, fuel injectors, ignition coils, ignition noise suppression capacitors, EGR valve, cam position sensor, oil pressure sending unit, etc).

152. Install the intake manifold onto the engine and tighten the bolts to 105 in. lbs. (12 N.m).

153. Install the two intake manifold support brackets and tighten.

154. Install oil fill tube and tighten bolt.

155. Install the EGR tube and a new gasket to the EGR valve. Finger-start the bolts.

156. Install the EGR tube into the intake manifold and tighten bolts to 95 in. lbs. (11 N.m).

157. Tighten the two EGR tube bolts at the EGR valve to 95 in. lbs. (11 N.m).

158. Tighten the EGR tube bracket bolt to 30 ft. lbs. (41 N.m).

159. Install the PVC valve into the valve cover.

160. Install the crankshaft damper and tighten the bolt to 70 ft. lbs. (95 N.m).

161. Install the PCV hose.

162. Attach the engine wire harness to the harness support bracket.

163. Connect the harness to the MAP sensor.

164. Connect the harness to the intake manifold short runner actuation valve.

165. Connect the harness to the intake manifold long runner actuation valve.

166. Connect the harness to the TPS on the throttle body.

167. Connect the harness to the IAC on the throttle body.

168. Install the three accessory drive idler pulleys onto the engine and tighten the bolts to 250 in. lbs. (28 N.m).

169. Install the accessory drive tensioner and tighten the bolt to 40 ft. lbs. (54 N.m).

170. Install the power steering pump and tighten the bolts to 21 ft. lbs. (28 N.m).

171. Install the power steering pump reservoir and tighten the bolts to 200 in. lbs. (23 N.m).

172. Install the generator and bracket. Tighten the lower two generator bolts to 40 ft. lbs. (54 N.m). Leave the bracket bolts finger tight.

173. Install the serpentine belt.

174. Install the right axle shaft into the transaxle (or PTU).

175. Position the suspension cradle fixture underneath the vehicle.

176. Lower the vehicle onto the suspension cradle.

177. Align the suspension cradle with the paint marks made in Step 68.

178. Install the four suspension cradle bolts and tighten to 120 ft. lbs. (163 N.m).

179. Install right (upper) engine mount. Tighten the timing cover bolts to 40 ft. lbs. (54 N.m). Tighten the right rail mounting bolts to 50 ft. lbs. (68 N.m).

180. Raise the vehicle and remove the suspension cradle support fixture.

181. Connect the crank position sensor to the wiring harness.

182. Install both engine mount-to-suspension cradle nuts and tighten to 120 ft. lbs. (163 N.m).

183. Align steering gear input shaft and install coupling pin.

184. For AWD models.

a. Install the engine/transaxle assembly support plate (AWD model only) and tighten the bolts to 40 ft. lbs. (54 N.m).

b. Align the propeller shaft from the rear differential to the PTU with the paint mark made in Step 65(a).

c. Install the propeller shaft to the rear differential into the PTU. Tighten the bolts to 22 ft. lbs. (30 N.m).

185. Position the brake lines and install the brake line spacer isolator on the left side of the engine compartment by the brake hydraulic control unit.

186. Position the exhaust system in the vehicle.

187. Install the vehicle rear exhaust system hanger bolts.

188. Install the vehicle center exhaust system hanger bolts.

189. Locate the exhaust pipe onto the engine exhaust manifold studs.

190. Position the heat shield tab onto the exhaust manifold stud.

191. Install the two nuts to the exhaust manifold studs and tighten to 25 ft. lbs. (34 N.m).

192. Connect the mid catalyst oxygen sensor to the electrical harness.

193. Attach the mid-catalyst oxygen sensor electrical harness fastener to the suspension cradle and tighten the bolt.

194. Install the torque converter drive plate bolts and tighten to 65 ft. lbs. (88 N.m).





195. Assemble the right axle to the right steering knuckle (Figure 46).

196. Assemble the right steering knuckle to the strut and install the pinch bolts.

Tighten the bolts to 65 ft. lbs. (88 N.m) + 90 (Figure 46).

197. Install the right axle hub nut. Tighten the nut to 180 ft. lbs. (244 N.m) and install retainer and cotter pin (Figure 46).

198. Install the right sway bar link to the right front strut and tighten the nut to 65 ft. lbs. (88 N.m) (Figure 46).

199. Install the right wheel speed sensor and retainer. Tighten the bolt to 96 in. lbs. (11 N.m).

200. Install the left fascia and tighten the screws.

201. Install the ground cable to the transaxle housing.

202. Assemble the left axle shaft into the left steering knuckle.

203. Assemble the left steering knuckle to the left strut. Install the pinch bolts and tighten the bolts to 65 ft. lbs. (88 N.m) + 90 (Figure 46).

204. Install the left axle hub nut. Tighten the nut to 180 ft. lbs. (244 N.m) and install retainer and cotter pin.

205. Install the left sway bar link to the left front strut. Tighten the nut to 65 ft. lbs. (88 N.m) (Figure 46).

206. Install the left wheel speed sensor and retainer. Tighten the bolt to 8 ft. lbs. (11 N.m).

207. Connect the engine wire harness to the PCM.

208. Install both the right and left inner fender liners.

209. Install the right and left wheel/tire assemblies and tighten the lug nuts to 110 ft. lbs. (149 N.m).

210. Lower the vehicle.

211. Connect the front oxygen sensor to the electrical wire harness.

212. Connect the engine harness to the chassis harness.

213. Attach the starter electrical harness to the starter.

214. Connect the duty cycle purge solenoid to the electrical harness.

215. Connect the generator to the electrical harness.

216. Connect the air conditioning clutch to the electrical harness.

217. Remove the caps from the air conditioning compressor and lines. Install the lines to the air conditioning compressor and tighten the fasteners to 204 in. lbs. (23 N.m).

218. Install the front right and left brake lines. Remove the prop from the brake pedal.

219. Install the heater hoses.

220. Install the hose to the coolant recovery bottle.

221. Install the block heater (if so equipped) 110 v power cord to the heater element.

222. Connect the transaxle oil cooler lines at the radiator.

223. Connect the transaxle selector shifter cable.

224. Install the engine wire harness ground at the left inner frame rail.

225. Install the transaxle electrical harness clip into the transaxle housing.

226. Connect the transaxle solenoid packs to the electrical harness.

227. Connect the transaxle range sensor to the electrical harness.

228. Connect the transaxle output speed sensor to the electrical harness.

229. Connect the transaxle multi-pin connector to the electrical harness.

230. Connect the vacuum lines to the intake manifold (brake booster, speed control servo, HVAC, etc).

231. Connect the throttle cables to the throttle body.

232. Install the lower radiator hose.

233. Install the air cleaner box.

234. Connect the wire harness to the air temperature sensor located in the air cleaner box.

235. Install the upper radiator hose.

236. Install the radiator cooling fans.

237. Install the radiator core support.

238. Install the cruise control solenoid and vacuum reservoir. Tighten the fasteners.

239. Connect the cruise control cable to the throttle body.

240. Bleed and fill the cooling system.

241. Bleed and fill the brake system.

242. Remove the caps from the fuel lines.

243. Connect the chassis fuel line to the engine fuel rail.

244. Install a new oil filter.

245. Install 5-1/2 quarts of new 10W30 engine oil.

246. Connect the battery.

247. Start the engine and check for leaks.

248. Raise the vehicle while the engine is idling.

249. Carefully tighten ONLY THE LOWER TWO air conditioning compressor bolts to 200 in. lbs. (23 N.m).

WARNING:
Keep hands and tools away from the moving serpentine belt while tightening the air conditioning compressor mounting bolts.

250. Lower the vehicle and turn off the ignition.

251. Raise the vehicle and tighten the four air conditioning compressor bolts to 200 in. lbs. (23 N.m).

252. Install the right wheel well lower splash shield.

253. Lower the vehicle.

254. Evacuate and charge the air conditioning system.

255. Install engine trim cover.

256. Return vehicle to the customer.