Engine Replacement - Manual Transmission
REMOVAL PROCEDURE^ Tools Required
- J 28467-360 Engine Support Fixture
Caution: Refer to Battery Disconnect Caution in Service Precautions.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure in Powertrain Management.
3. Drain and recover the coolant. Refer to Cooling System Service and Repair.
4. Remove the air cleaner outlet duct (1).
5. Remove the upper radiator hose at the coolant outlet.
6. Disconnect the brake booster vacuum hose.
7. Disconnect the IAC electrical connection.
8. Disconnect the generator electrical connection.
9. Disconnect the Throttle Position (TPS) Sensor electrical sensor.
10. Disconnect the MAP electrical connection.
11. Disconnect the EVAP emission solenoid electrical connection.
12. Disconnect the injector harness electrical connection.
13. Disconnect the EGR electrical connection.
14. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connection.
15. Disconnect the Oxygen (02S) sensor electrical connection.
16. Disconnect the engine grounds electrical connection.
17. Remove the drive belt.
18. Disconnect the transmission shift control cable from the lever and bracket.
19. Remove the coolant surge tank.
20. Disconnect the vacuum line near the master cylinder.
21. Install the engine support fixture.
22. Disconnect the lower radiator hose from the coolant pump.
23. Raise the vehicle. Refer to Vehicle Lift Points.
24. Remove the front tire and wheel assemblies.
25. Remove both of the splash shields.
26. Remove the exhaust pipe at the exhaust manifold and catalytic converter.
27. Remove the engine mount strut.
28. Remove the wheel speed sensor wire harness from the control arms.
29. Separate the ball joints from the steering knuckles.
30. Separate the tie rod ends from the struts.
31. Remove the brake lines from the suspension support below the rack and pinion.
32. Disconnect the A/C compressor electrical connector.
33. Remove the A/C compressor and support with the lines attached.
34. Disconnect the electronic ignition module electrical connection.
35. Disconnect the vehicle speed sensor electrical connections.
36. Disconnect the cooling fan electrical connection.
37. Disconnect the starter electrical connection.
38. Disconnect the oil pressure sensor electrical connector.
39. Disconnect the ground wires.
40. Disconnect the power steering lines from the rack and pinion assembly.
41. Remove the flexible coupling joint at the rack and pinion assembly.
42. Remove the following cables from the accelerator control bracket:
^ The accelerator control (2).
^ The cruise control (1).
43. Remove the suspension support center bolts.
44. Remove the suspension support outer bolts.
45. Remove the suspension support upper bolts and the support.
46. Disconnect the heater hoses at the front of the dash.
47. Remove both of the drive axles from the transmission and position them aside.
48. Disconnect the fuel lines.
49. Remove the transmission mount thru bolts.
50. Remove the engine mount assembly.
51. Lower the vehicle until it rests lightly against the support.
52. Remove the J 28467-360 from the engine.
53. Raise the vehicle. Refer to Vehicle Lift Points. Leave the engine and the transmission assembly on the table.
54. Remove the engine from the transmission.
INSTALLATION PROCEDURE
^ Tools Required
- J 28467-360 Engine Support Fixture
1. Install the engine to the transmission.
Notice: Refer to Fastener Notice in Service Precautions.
2. Install the transmission bolts.
^ Tighten the bolts to 75 Nm (55 ft. lbs.).
3. Lower the vehicle onto the engine and transmission assembly.
4. Install the engine support fixture.
5. Install the engine mount assembly.
6. Install the transmission mount.
7. Install both of the drive axles.
8. Connect the heater hoses.
9. Install the suspension support upper bolts and the support.
10. Install the suspension support outer bolts.
11. Install the suspension support center bolts.
12. Install the following cables to the accelerator control bracket:
^ The accelerator control (2).
^ The cruise control (1)
13. Install the flexible coupling joint to the rack and pinion assembly.
14. Connect the power steering lines.
15. Install the electronic ignition module electrical connection.
16. Connect the brake lines to the suspension support.
17. Connect the vehicle speed sensor electrical connections.
18. Connect the cooling fan electrical connection.
19. Connect the starter electrical connection.
20. Connect the oil pressure sensor electrical connection.
21. Connect the oil level sensor electrical connection.
22. Connect the grounds electrical connection
23. Connect the oil level sensor electrical connection.
24. Install the A/C compressor.
25. Install the tie rod ends to the struts.
26. Install the ball joints to the steering knuckles.
27. Install the wheel speed sensor wire harness to the control arms.
28. Install the engine mount strut.
29. Install the exhaust pipe to the exhaust manifold and catalytic converter.
30. Install both of the splash shields.
31. Install the front tire and wheel assemblies.
32. Lower the vehicle.
33. Connect the lower radiator hose to the coolant pump.
34. Remove the engine support fixture.
35. Connect the vacuum line near the master cylinder.
36. Install the coolant surge tank.
37. Connect the transmission shift control cables.
38. Install the drive belt.
39. Install the IAC electrical connection.
40. Connect the generator electrical connection.
41. Connect the Throttle Position (TPS) Sensor electrical connection.
42. Connect the MAP electrical connection.
43. Connect the EVAP emission solenoid electrical connector.
44. Connect the EGR electrical connector.
45. Connect the injector harness.
46. Connect the Engine Coolant Temperature (ECT) sensor electrical connector.
47. Reconnect the Oxygen (02S) sensor.
48. Reconnect the engine ground wires.
49. Connect the brake booster vacuum hose.
50. Install the upper radiator hose at the coolant outlet.
51. Install the air cleaner outlet duct.
52. Fill the coolant system. Refer to Cooling System Service and Repair.
53. Refill the engine with oil.
54. Reconnect the negative battery cable.
^ Tighten the bolt to 16 Nm (12 ft. lbs.).
55. Connect the fuel lines.
56. Start the engine and check for leaks.
57. Turn the engine OFF and recheck the fluid levels.