Engine Replacement

Removal Procedure

- Tools Required
- J 28467-360 Engine Support Fixture
- J 24420-C Crankshaft Balancer Puller
- J 34730-250 Fuel Pressure Gauge and Adapter
- J 36018 Belt Tensioner
- J 38122-A Crankshaft Balancer Holder

1. Drain the engine coolant.
2. Drain the Engine Oil.
3. Remove the fuel rail assembly.
4. Remove the air intake duct from the air cleaner.
5. Disconnect and remove the ignition coil and the module assembly.





6. Disconnect the camshaft position sensor.





7. Remove the power steering pump and set aside with the lines attached.





8. Disconnect the oil pressure sending switch.
9. Remove the air intake duct bracket.
10. Remove the cruise control assembly and set aside.
11. Install the engine support fixture.
12. Remove the engine mount assembly.





13. Disconnect the vacuum line at the fuel pressure regulator.
14. Raise the engine with the engine support fixture J-hook.
15. Remove the engine mount bracket.
16. Lower the engine.
17. Remove the drive belt.
18. Remove the front wheels.
19. Remove the right front splash shield.
20. Remove the crankshaft balancer.
21. Lower the vehicle.





22. Disconnect the following electrical connectors:
- The MAP sensor
- The IAT sensor
- The evaporator canister
- The EGR sensor
23. Remove the generator.





Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.
In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.

24. Remove the accelerator cable bracket.
25. Remove the starter.





26. Remove the exhaust brace bolt in the exhaust manifold.





27. Remove the exhaust manifold heat shield.





28. Disconnect the exhaust pipe from the exhaust manifold.
29. Remove the engine intake coolant pipe.
30. Remove the torque converter bolts.
31. Raise and support the vehicle.





32. Remove the oxygen sensor.
33. Remove the A/C compressor bolts. Position the compressor out of the way.
34. Remove the bolts which secure the oil pan to the bell housing.
35. Remove the transmission mount.
36. Remove the bolts which secure the transaxle to the engine.
37. Install the engine lifting device. Support the transaxle.
38. Raise the engine slightly and separate the engine from the transaxle.





39. Remove the flywheel bolts and the flywheel.
40. Mount the engine on a suitable engine stand.


Installation Procedure

- Tools Required
- J 28467-360 Engine Support Fixture
- J 24420-C Crankshaft Balancer Puller
- J 34730-250 Fuel Pressure Gauge and Adapter
- J 36018 Belt Tensioner
- J 38122-A Crankshaft Balancer Holder





1. Install the flywheel, the retainer and the bolts.
2. Tighten the bolts evenly while holding the balancer with the J 38122-A.
3. Attach the engine lifting device to the engine.
4. Install the engine into the vehicle and align the transaxle to the engine.
5. Install the bolts which secure the transaxle to the engine.
6. Install the transaxle mount.
7. Install the engine support fixture.
8. Raise and support the vehicle. Refer to Vehicle Lifting.
9. Install the coolant pipe and the thermostat.
10. Install the transaxle brace.
11. Install the stud and the nut which secure the oil pan to the transaxle housing.





12. Install and connect the oxygen sensor.





13. Connect the exhaust pipe.





14. Install the exhaust manifold heat shield.





15. Install the exhaust manifold brace bolts.
16. Lower the vehicle.
17. Install the torque converter bolts.
18. Install the starter.
19. Install the generator.





Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.
In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.

20. Install the accelerator cable bracket.





21. Install the vacuum hoses at the fuel pressure regulator and at the evaporator module.





22. Connect the following electrical connectors:
- The MAP sensor
- The IAT sensor
- The Evaporator canister
- The EGR sensor
23. Raise and support the vehicle. Refer to Vehicle Lifting.
24. Install the crankshaft balancer.
25. Install the right front splash shield.
26. Install the front wheels.
27. Lower the vehicle.
28. Install the drive belt.
29. Raise the engine with the support fixture J-hook.
30. Install the engine mount and the mount bracket.
31. Remove the engine support fixture.
32. Install the cruise control assembly.





33. Connect the oil pressure switch.





34. Install the power steering pump.





35. Connect the camshaft position sensor.
36. Install the air intake assembly.
37. Install the fuel rail assembly.
38. Install the ignition coil and module.
39. Refill the engine oil.
40. Refill the engine cooling system.
41. Run the engine to operating temperature and retest all fluid levels.