Engine Replacement

Engine Replacement

Removal Procedure

1. Remove the fuel injector sight shield.
2. Release the clamp from the brake booster vacuum hose connection.
3. Disconnect the brake booster vacuum hose from the intake manifold.
4. Remove the air cleaner assembly.
5. Discharge the fuel system. Refer to Fuel Pressure Relief (With CH 48027-100) Fuel Pressure Relief (Without CH 48027-100).
6. Disconnect the evaporative emission (EVAP) hose/pipe from the EVAP canister purge solenoid valve.
7. Disconnect the engine fuel hose/pipe from the chassis fuel hose/pipe.
8. Discharge the air conditioning (A/C) system. Refer to Refrigerant Recovery and Recharging.
9. Remove the A/C compressor suction hose assembly from the compressor. Cap or plug the hoses and compressor to prevent contamination. Refer to Suction Hose Replacement.
10. Remove the A/C compressor discharge hose assembly from the compressor. Cap or plug the hoses and compressor to prevent contamination. Refer to Discharge Hose Replacement.
11. Drain the engine coolant from the cooling system.
12. Tie the radiator, A/C condenser, and fan module assembly to the upper radiator support to keep the assembly with the vehicle when the frame and drivetrain is removed.
13. Remove the coolant recovery reservoir.
14. Disconnect the inlet coolant heater hose from the engine.
15. Disconnect the outlet coolant heater hose from the engine.
16. Remove the radiator inlet hose.
17. Raise and support the vehicle. Refer to Vehicle Lifting.
18. Remove the radiator outlet hose.
19. Remove the exhaust flexible pipe and secure the rear half of the exhaust system to the vehicle underbody.
20. Remove the front tires.
21. Remove the engine splash shield.
22. Remove the steering intermediate shaft pinch bolt and discard the bolt.
23. Disconnect the steering intermediate shaft from the steering gear.




24. Remove the right and left steering linkage outer tie rod ends from the steering knuckles.




25. Remove the right and left stabilizer shaft links from the stabilizer shaft.




26. Remove the right and left lower ball joints from the steering knuckles.
27. On front wheel drive (FWD) models, place a drain pan under the transaxle then separate the right and left front wheel drive shafts from the transaxle. Refer to Front Wheel Drive Shaft Replacement.
28. On all wheel drive (AWD) models, remove the driveline torque tube.




29. On all models, place a block of wood (1) between the frame and the engine oil pan in order to support the engine once the bolts are removed from the right engine mount.




30. Place a block of wood (1) between the frame and the transaxle in order to support the transaxle once the bolts are removed from the left transaxle mount bracket.
31. Lower the vehicle.
32. Remove the engine mount strut.
33. Remove the left transaxle mount bracket.

Important: Insure the vehicle body is secured to the hoist.

34. Raise the vehicle.
35. Place a universal frame support fixture or jackstands under the frame.
36. Lower the vehicle until the frame contacts the frame support fixture or jackstands.




37. Remove the frame-to-body bolts. Discard the bolts.

Important: Inspect for areas of body to powertrain contact or entanglement of wires and hoses while separating the vehicle body and powertrain.

38. Carefully raise the vehicle body up away from the powertrain.




39. Disconnect the engine electrical wiring harness from the following components:
^ Oxygen sensor (1)
^ EVAP purge solenoid (2)
^ Ignition coils (3, 4, 10)
^ Ground leads (7, 11)
^ Remove wire harness from retainers (5, 6, 8, 9)




40. Disconnect the left and right cylinder head engine electrical wiring harness from the following components:
^ Camshaft position sensors (1)
^ Camshaft position actuators (2)




41. Disconnect the engine electrical wiring harness from the following components:
^ Generator (1)
^ Retainer clips (2, 3, 4, 5, 6, 7, 9)
^ A/C compressor hose (8)
^ Oil pressure switch (10)
^ A/C compressor (8)




42. Disconnect the engine electrical wiring harness from the following components:
^ Battery cable (1)
^ Retainer clips (2, 3)
^ Transmission module (4)




43. If equipped with an engine coolant heater, disconnect the coolant heater cord.
44. Remove the throttle body assembly.
45. Remove the engine-to-transaxle brace bolts and brace.
46. Remove the starter motor.




47. Remove the torque converter bolts.
48. Install an engine lift chain to the engine lift brackets.
49. Support the engine weight with an engine hoist.




50. Remove the automatic transaxle bolts.
51. Separate the automatic transaxle from the engine.
52. Lift the engine away from the frame and the automatic transaxle.
53. Secure the engine to an engine stand.
54. Remove any additional engine components as necessary.

Installation Procedure

1. Remove the engine from the engine stand.




2. Align the engine to the frame and automatic transaxle.

Notice: Refer to Fastener Notice.

3. Install the automatic transaxle bolts.

Tighten the bolts to 75 N.m (55 lb ft).

4. Place a block of wood between the frame and the engine oil pan in order to support the engine on the frame once the engine hoist is removed.
5. Remove the engine hoist and lift chain.




6. Install the torque converter bolts.

Tighten the bolts to 60 N.m (44 lb ft).

7. Install the starter motor.
8. Install the engine to transaxle brace and bolts.

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

9. Install the throttle body assembly.




10. If equipped with an engine coolant heater, connect the coolant heater cord.




11. Connect the engine electrical wiring harness to the following components:
^ Transmission module (4)
^ Retainer clips (3, 2)
^ Battery cable (1)

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




12. Connect the engine electrical wiring harness to the following components:
^ A/C compressor (8)
^ Oil pressure switch (10)
^ A/C compressor hose (8)
^ Retainer clips (2, 3, 4, 5, 6, 7, 9)
^ Generator (1)

Tighten the nut to 13 N.m (115 lb in).




13. Connect the left and right cylinder head engine electrical wiring harness to the following components:
^ Camshaft position actuators (2)
^ Camshaft position sensors (1)




14. Connect the engine electrical wiring harness to the following components:
^ Install wire harness to retainers (5, 6, 8, 9)
^ Ground leads (7, 11)
^ Ignition coils (3, 4, 10)
^ EVAP purge solenoid (2)
^ Oxygen sensor (1)




15. Install NEW frame-to-body bolts.

Tighten the bolts to 155 N.m (114 lb ft).

16. Raise the vehicle up away from the frame support fixture or jackstands and remove the support fixture or jackstands from under the vehicle.
17. Lower the vehicle.
18. Install the left transaxle mount bracket.
19. Install the engine mount strut.
20. Raise the vehicle.




21. Remove the block of wood (1) between the frame and the transaxle used to support the transaxle while the bolts were removed from the left transaxle mount bracket.




22. Remove the block of wood (1) between the frame and the engine oil pan used to support the engine while the bolts were removed from the right engine mount.
23. On AWD models, Install the driveline torque tube.
24. On FWD models, install the right and left front wheel drive shafts into the transaxle.




25. On all models, install the right and left lower ball joints to the steering knuckles. Refer to Lower Control Arm Replacement.




26. Install the right and left stabilizer shaft links to the stabilizer shaft.




27. Install the right and left steering linkage outer tie rod ends to the steering knuckles.
28. Connect the steering intermediate shaft to the steering gear.
29. Install a NEW pinch bolt to the steering intermediate shaft.

Tighten the bolt to 34 N.m (25 lb ft).

30. Install the engine splash shield.
31. Install the front tires.
32. Install the exhaust flexible pipe.
33. Install the radiator outlet hose.
34. Lower the vehicle.
35. Install the radiator inlet hose.
36. Connect the outlet coolant heater hose to the engine.
37. Connect the inlet coolant heater hose to the engine.
38. Install the coolant recovery reservoir.
39. Untie the radiator, AC condenser, and fan module assembly from the upper radiator support.
40. Install the A/C compressor discharge hose assembly to the compressor.
41. Install the A/C compressor suction hose assembly to the compressor.




42. Connect the engine fuel hose/pipe (3) to the chassis fuel hose/pipe (2).
43. Connect the EVAP hose/pipe to the EVAP canister purge solenoid valve.
44. Install the air cleaner assembly.




45. Connect the brake booster vacuum hose (2) to the intake manifold.
46. Position the clamp (1) on the brake booster vacuum hose connection.
47. Install the fuel injector sight shield.
48. Fill the engine with engine oil. Refer to Approximate Fluid Capacities, Fluid and Lubricant Recommendations, and Maintenance Schedule (North American Emissions).
49. Fill the engine with coolant. Refer to Draining and Filling Cooling System (Static Fill) Draining and Filling Cooling System (Vac N Fill).
50. Check the transaxle fluid level. Refer to Sealers, Adhesives, and Lubricants, Transmission General Specifications, and Approximate Fluid Capacities.
51. Charge the AC system. Refer to Refrigerant Recovery and Recharging.
52. Prime the fuel system.
1. Cycle the ignition ON for 5 seconds then OFF for 10 seconds. Repeat cycling twice.
2. Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds.
3. If the engine does not start, repeat the steps.