Engine Replacement - Manual Transmission

Removal Procedure





1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging.
2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
3. Evacuate the A/C System. Refer to Refrigerant Recovery and Recharging in Heating and Air Conditioning.
4. Remove the air cleaner duct.
5. Remove the air cleaner.
6. Remove the underhood fuse block.
7. Remove the air cleaner bracket.
8. Disconnect the shift cables at the shift control.





9. Remove the shift cables from the bracket and remove the bracket.





10. Disconnect the back up lamp switch.





11. Disconnect the vehicle speed sensor.
12. Disconnect the engine controls harness.
13. Disconnect the vacuum lines.
14. Relieve the fuel pressure. Refer to Fuel Pressure Release.
15. Disconnect the fuel line quick disconnects. Refer to Quick Connect Fitting(s) Service (Metal Collar) in Powertrain Management.
16. Remove the radiator hoses. Refer to Radiator Hose Replacement in Cooling System.
17. Disconnect the heater hoses from the heater core. Refer to Heater Hoses Replacement in Heating and Air Conditioning.





18. Disconnect the slave cylinder hydraulic line.
19. Remove the EVAP solenoid. Refer to EVAP Canister Purge Solenoid Valve Replacement in Powertrain Management.
20. Disconnect the ground cables at the rear of the engine block.
21. Remove the power steering pump with lines attached and position the pump out of the way.
22. Disconnect the electrical connector from the A/C compressor and the CKP. Position the harness aside.
23. Remove the starter with the wires attached and position it out of the way. Refer to Starter Motor Replacement in Starting and Charging.
24. Disconnect the surge tank bypass hose from the engine. Refer to Surge Tank Replacement in Cooling System.
25. Disconnect the cruise and accelerator cables from the throttle body. Refer to Accelerator Controls Cable Replacement in Powertrain Management.
26. Remove and position aside the cruise control module. Refer to Cruise Control Module Replacement in Cruise Control.
27. Tie the radiator to the hood latch panel with mechanics wire.
28. Raise and support the vehicle. Refer to Lifting Vehicle.
29. Safety strap the front of the vehicle to the hoist.
30. Drain the transaxle.
31. Drain the engine oil and remove the oil filter. Refer to Engine Oil and Oil Filter Replacement.
32. Remove the front splash shields. Splash Shield Replacement - Wheelhouse in Body and Frame.
33. Remove the front closeout panel fasteners and the panel.
34. Remove the lower radiator support. Refer to Radiator Support Replacement.
35. Remove the right front brake hose from the vehicle. Refer to Brake Hose Replacement - Front in Brakes and Traction Control.
36. Remove the retaining nut from the BPMV at the mounting bracket. Refer to Brake Modulator Assembly Replacement in Brakes and Traction Control.





37. Disconnect the wheel speed sensors.





38. Remove the wheel speed sensor harnesses from the control arm retainers.





39. Remove the wheel speed sensor harnesses from the frame retainers and position them out of the way.
40. Remove the wheel driveshafts. Refer to Wheel Drive Shafts Replacement in Transmission and Drivetrain.
41. Disconnect the ball joints from the control arms. Refer to Lower Ball Joint Replacement in Steering and Suspension.
42. Disconnect the outer tie rod ends from the control arms. Refer to Tie Rod End Replacement - Outer in Steering and Suspension.
43. Disconnect the catalytic converter from the exhaust manifold. Refer to Catalytic Converter Replacement in Powertrain Management.
44. Remove the A/C compressor hose from the A/C compressor. Refer to Compressor Hose Assembly Replacement in Heating and Air Conditioning.
45. Remove the bolt from the power steering pressure line retainer. Refer to Power Steering Pressure Hose Replacement in Steering and Suspensions.
46. Lower the vehicle until the front suspension crossmember rests on the support table.
47. Position a three inch block of wood between the front of the oil pan and the crossmember.
48. Remove the front engine mount to bracket bolts. Refer to Engine Mount Replacement.
49. Remove the front suspension crossmember retaining bolts.
50. With the help of an assistant, carefully raise the vehicle off of the engine/transaxle assembly.
51. Install the engine hoist to the engine/transmission assembly.





52. Remove the front transmission mount thru bolt.





53. Remove the rear transmission mount thru bolt.





54. Remove the two side transmission mount lower nuts.
55. Lift the engine/transaxle assembly off of the front suspension crossmember.
56. Separate the transaxle from the engine. Refer to Transmission Replacement.
57. Remove the clutch drive plate and clutch driven plate.
58. Remove the flywheel. Refer to Engine Flywheel Replacement.
59. Mount the engine on a suitable engine stand.

Installation Procedure





1. Remove the engine from the engine stand.
2. Install the flywheel to the engine. Refer to Engine Flywheel Replacement.
3. Install the clutch driven plate and clutch drive plate.
4. Install the transaxle to the engine.
5. Lower the engine/transaxle assembly on to the front suspension crossmember.

Notice: Refer to Fastener Notice in Service Precautions.

6. Install the two side transmission mount lower nuts.
^ Tighten the nuts to 44 Nm (60 ft. lbs.).





7. Install the rear transmission mount thru bolt.
^ Tighten the rear transmission mount thru bolt to 55 Nm (75 ft. lbs.).





8. Install the front transmission mount thru bolt.
^ Tighten the front transmission thru bolt to 55 Nm (75 ft. lbs.).
9. Remove the engine noise from the engine/transaxle assembly.
10. With the help of an assistant, carefully lower the vehicle on to the engine/transaxle assembly.
11. Install the front suspension crossmember retaining bolts.
12. Install the front engine mount to bracket bolts. Refer to Engine Mount Replacement.
13. Raise the vehicle off of the support table.
14. Install the bolt to the power steering pressure line retainer. Refer to Power Steering Pressure Hose Replacement in Steering and Suspensions.
15. Install the A/C compressor hose to the A/C compressor. Refer to Compressor Hose Assembly Replacement in Heating and Air Conditioning.
16. Connect the catalytic converter to the exhaust manifold. Refer to Catalytic Converter Replacement in Powertrain Management.
17. Connect the outer tie rod ends to the control arms. Refer to Tie Rod End Replacement - Outer in Steering and Suspension.
18. Connect the ball joints to the control arms. Refer to Lower Ball Joint Replacement in Steering and Suspension.
19. Install the wheel driveshafts. Refer to Wheel Drive Shafts Replacement in Transmission and Drivetrain.





20. Install the wheel speed sensor harnesses to the frame retainers. Ensure the retainers lock into position.





21. Install the wheel speed sensor harnesses to the control arm retainers. Ensure that the retainers lock into position.





22. Connect the wheel speed sensors.
23. Install the retaining nut to the BPMV at the mounting bracket. Refer to Brake Modulator Assembly Replacement in Brakes and Traction Control.
24. Install the right front brake hose to the vehicle. Refer to Brake Hose Replacement - Front in Brakes and Traction Control.
25. Install the lower radiator support. Refer to Radiator Support Replacement.
26. Install the front closeout panel and the panel fasteners. Ensure the fasteners are retained.
27. Install the front splash shields.
28. Install a new oil filter and fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement.
29. Fill the transaxle with specified lubricant.
30. Remove the safety straps from the front of the vehicle and the hoist.
31. Lower the vehicle.
32. Untie the radiator from the hood latch panel.
33. Install the cruise control module. Refer to Cruise Control Module Replacement in Cruise Control.
34. Connect the cruise and accelerator cables to the throttle body. Refer to Accelerator Controls Cable Replacement in Powertrain Management.
35. Connect the surge tank bypass hose to the engine. Refer to Surge Tank Replacement in Cooling System.
36. Install the starter. Refer to Starter Motor Replacement in Starting and Charging.
37. Connect the electrical connectors to the A/C compressor and the CKP.
38. Install the power steering pump. Refer to Power Steering Pump Replacement in Steering and Suspensions.
39. Connect the ground cables at the rear of the engine block.
40. Install the EVAP solenoid. Refer to EVAP Canister Purge Solenoid Valve Replacement in Powertrain Management.





41. Connect the slave cylinder hydraulic line.
42. Connect the heater hoses to the heater core. Refer to Heater Hoses Replacement in Heating and Air Conditioning.
43. Connect the radiator hoses. Refer to Radiator Hose Replacement in Cooling System.
44. Connect the fuel line quick disconnects. Refer to Quick Connect Fitting(s) Service (Metal Collar) in Powertrain Management.
45. Connect the vacuum lines. Refer to Emission Hose Routing Diagram in Powertrain Management.
46. Connect the engine controls harness.





47. Connect the VSS.





48. Connect the back up lamp switch.





49. Install the shift cable bracket and the shift cables to the bracket.





50. Connect the shift cables at the shift control.
51. Install the air cleaner bracket.
52. Install the underhood fuse block.
53. Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Powertrain Management.
54. Install the air cleaner duct. Refer to Air Cleaner Intake Duct Replacement in Powertrain Management.
55. Charge the A/C system. Refer to Refrigerant Recovery and Recharging in Heating and Air Conditioning.
56. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
57. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging.