Engine Replacement

Removal Procedure

^ Tools Required
- J39580 Universal Engine Support Table





1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging.
2. Remove the drive belt. Refer to Drive Belt Replacement.
3. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.
4. Remove the power steering pump from the engine. Position the power steering pump aside. Refer to Power Steering Pump Replacement in Steering and Suspension.





5. Remove the throttle body air inlet duct (3). Refer to Air Cleaner Intake Duct Replacement in Powertrain Management.
6. Remove the engine mount strut from the engine mount strut bracket. Refer to Engine Mount Strut Replacement.

Important: Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure in Powertrain Management.





7. Disconnect the fuel lines from the fuel rail. Lay the fuel lines aside. Refer to Quick Connect Fitting(s) Service (Metal Collar) or Quick Connect Fitting(s) Service (Plastic Collar) in Powertrain Management.
8. Disconnect the fuel vapor line.

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.

9. Disconnect the throttle and cruise cables with the mounting bracket from the throttle body. Refer to Accelerator Controls Cable Replacement and Accelerator Controls Cable Bracket Replacement in Powertrain Management.
10. Disconnect the automatic range selector cable from the PNP switch. Refer to Automatic Transmission Range Selector Cable Replacement (At PNP Switch) or Automatic Transmission Range Selector Cable Replacement (At Shift Control) or Automatic Transmission Range Selector Cable Replacement (New Cable Installation) in Transmission and Drivetrain.





11. Disconnect the vacuum booster hose from the engine. Refer to Vacuum Brake Booster Hose Replacement in Brakes and Traction Control.





12. Disconnect the A/C vacuum hose from the engine.
13. Disconnect the wiring harness connections from the engine and transmission. Refer to Engine Control Component Views in Powertrain Management.
14. Drain the engine coolant from the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
15. Disconnect the radiator inlet hose from the engine. Refer to Radiator Hose Replacement - Inlet in Cooling System.
16. Disconnect the transaxle oil cooler lines from the radiator. Refer to Automatic Transmission Oil Cooler Hose Replacement in Transmission and Drivetrain.
17. Remove the thermostat housing. Refer to Thermostat Replacement in Cooling System.
18. Disconnect the surge tank inlet hose. Refer to Surge Tank Hose Replacement (Inlet) or Surge Tank Hose Replacement (Outlet) in Cooling System.
19. Disconnect the heater hoses from the engine. Refer to Heater Hoses Replacement in Heating and Air Conditioning.
20. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
21. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement.
22. Remove the lower radiator air deflector. Refer to Radiator Air Baffle Assemblies and Deflectors (Air Baffle) or Radiator Air Baffle Assemblies and Deflectors (Lower) or Radiator Air Baffle Assemblies and Deflectors (Side) in Cooling System.





23. Disconnect the AIR pipe from the AIR inlet valve. Refer to Sec Air Injection Check Valve/Pipe Replacement in Powertrain Management.
24. Remove the battery cables from the retainers.
25. Disconnect the radiator outlet hose from the engine. Refer to Radiator Hose Replacement - Outlet in Cooling System.
26. Remove the generator. Refer to Generator Replacement in Starting and Charging.
27. Remove the A/C compressor mounting bolts and nuts. DO NOT discharge the system. Secure the compressor. Refer to Compressor Replacement in Heating and Air Conditioning.
28. Remove the torque converter cover. Refer to Torque Converter Cover Replacement in Transmission and Drivetrain.
29. Remove the starter motor. Refer to Starter Motor Replacement in Starting and Charging.
30. Scribe the torque converter to the flywheel for installation.
31. Remove the engine flywheel-to-torque converter bolts. Refer to Flywheel to Torque Converter Bolts in Transmission and Drivetrain.
32. Remove the three-way catalytic converter pipe from the right (rear) exhaust manifold. Refer to Catalytic Converter Replacement in Powertrain Management.





33. Remove the lower transaxle-to-engine bolts.
34. Remove the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Steering and Suspension.
35. Remove the inner fender engine splash shield. Refer to Splash Shield Replacement - Engine in Body and Frame.
36. Disconnect the fog lamp electrical connectors.
37. Remove the wheel speed sensor harness conduits from the retainers in the lower control arms.
38. Remove the tie rod ends from the steering knuckles. Refer to Steering Knuckle Replacement in Steering and Suspension.
39. Remove the lower ball joints from the steering knuckles. Refer to Steering Knuckle Replacement in Steering and Suspension.
40. Disconnect the drive axles. Refer to Wheel Drive Shafts Replacement (Left) or Wheel Drive Shafts Replacement (Right) in Transmission and Drivetrain.
41. Secure the drive axles.

Caution: Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or damage to the Intermediate shaft. This damage may cause loss of steering control which could result in personal injury.

42. Remove the pinch bolt at the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement in Steering and Suspension.





43. Disconnect the intermediate shaft (1) from the steering gear (2). Refer to Intermediate Steering Shaft Replacement in Steering and Suspension.
44. Place the J39580 under the engine/transmission/frame.
45. Lower the vehicle to the frame table in order to support the engine/transmission/frame.
46. Suitably secure the vehicle to the hoist. Refer to Vehicle Lifting.
47. Remove the frame-to-body bolts. Refer to Frame Replacement in Body and Frame.

Important: Carefully adjust the A/C compressor as the vehicle is raised.

48. Raise and suitable support the vehicle. Refer to Vehicle Lifting.
49. Remove the frame table with the engine/transmission/frame from under the vehicle.
50. Remove the engine mount bracket-to-engine bolts. Refer to Engine Mount Bracket Replacement (Front) or Engine Mount Bracket Replacement (Rear).
51. Remove the transaxle brace. Refer to Automatic Transmission Brace Replacement in Transmission and Drivetrain.
52. Remove the upper transmission-to-engine bolts.





53. Remove the engine from the transmission/frame.

Installation Procedure





1. Install the engine. Align the engine with the engine-to-transmission dowel pins.

Notice: Refer to Fastener Notice in Service Precautions.

Important: The transmission-to-engine bolts must be returned to their original position. The bolt installed in position (5) is 2 mm shorter than the other transmission-to-engine bolts and requires the use of thread sealant.

2. Install the upper transmission-to-engine bolts.
Tighten the upper transmission-to-engine bolts to 75 Nm (55 ft. lbs.).
3. Install the transaxle brace. Refer to Automatic Transmission Brace Replacement in Transmission and Drivetrain.
4. Install the engine mount bracket to engine bolts. Refer to Engine Mount Bracket Replacement (Front) or Engine Mount Bracket Replacement (Rear).
5. Place the J39580 with the engine/transmission/frame under the vehicle.

Important: Carefully adjust the A/C compressor as the vehicle is lowered.

6. Lower the vehicle.
7. Install the frame-to-body bolts. Refer to Frame Replacement in Body and Frame.
8. Raise and suitably support the vehicle. Refer to Vehicle Lifting.





9. Remove the frame table from under the vehicle.

Caution: When installing the Intermediate shaft make sure that the shaft is seated prior to pinch bolt Installation. If the pinch bolt is inserted into the coupling before shaft installation, the two mating shafts may disengage. Disengagement of the two mating shafts will cause loss of steering control which could result in personal injury.

10. Connect the intermediate shaft (1) to the steering gear (2). Refer to Intermediate Steering Shaft Replacement in Steering and Suspension.
11. Install the pinch bolt at the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement in Steering and Suspension.
12. Install the drive axles to the transmission. Refer to Wheel Drive Shafts Replacement (Left) or Wheel Drive Shafts Replacement (Right) in Transmission and Drivetrain.
13. Install the lower ball joints to the steering knuckles. Refer to Steering Knuckle Replacement in Steering and Suspension.
14. Install the tie rod ends to the steering knuckles. Refer to Steering Knuckle Replacement in Steering and Suspension.
15. Install the wheel speed sensor harness conduits to the retainers in the lower control arms.
16. Install the inner fender engine splash shields. Refer to Splash Shield Replacement - Engine in Body and Frame.
17. Install the fog lamp electrical connectors.
18. Install the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Steering and Suspension.

Important: The transmission-to-engine bolts must be returned to their original position. The bolt installed in position (5) is 2 mm (0.08 inch) shorter than the other transmission-to-engine bolts and requires the use of thread sealant.





19. Install the lower transmission-to-engine bolt.
Tighten the lower transmission-to-engine bolts to 75 Nm (55 ft. lbs.).
20. Install the three-way catalytic converter pipe to the right (rear) exhaust manifold. Refer to Catalytic Converter Replacement in Powertrain Management.
21. Align the mark scribed on the torque converter to the mark scribed on the flywheel.
22. Install the engine flywheel-to-torque converter bolts. Refer to Flywheel to Torque Converter Bolts in Transmission and Drivetrain.
23. Install the starter motor. Refer to Starter Motor Replacement in Starting and Charging.
24. Install the torque converter cover. Refer to Torque Converter Cover Replacement in Transmission and Drivetrain.
25. Install the A/C compressor. Refer to Compressor Replacement in Heating and Air Conditioning.
26. Install the generator. Refer to Generator Replacement in Starting and Charging.
27. Connect the radiator outlet hose to the engine. Refer to Radiator Hose Replacement - Outlet in Cooling System.
28. Install the battery cables to the retainers.





29. Connect the AIR pipe to the AIR inlet valve. Refer to Sec Air Injection Check Valve/Pipe Replacement in Powertrain Management.
30. Install the lower radiator air deflector. Refer to Radiator Air Baffle Assemblies and Deflectors (Air Baffle) or Radiator Air Baffle Assemblies and Deflectors (Lower) or Radiator Air Baffle Assemblies and Deflectors (Side) in Cooling System.
31. Lower the vehicle and remove security to hoist.
32. Install the thermostat housing. Refer to Thermostat Replacement in Cooling System.
33. Install the heater hoses to the engine. Refer to Heater Hoses Replacement in Heating and Air Conditioning.
34. Install the surge tank inlet hose. Refer to Surge Tank Hose Replacement (Inlet) or Surge Tank Hose Replacement (Outlet) in Cooling System.
35. Connect the transaxle oil cooler lines to the radiator. Refer to Automatic Transmission Oil Cooler Hose Replacement in Transmission and Drivetrain.
36. Install the radiator inlet hose to the engine. Refer to Radiator Hose Replacement - Inlet in Cooling System.
37. Install the wiring harness connections to the engine and transaxle. Refer to Engine Control Component Views in Powertrain Management.





38. Connect the A/C vacuum hose to the engine.





39. Connect the vacuum booster hose to the engine. Refer to Vacuum Brake Booster Hose Replacement in Brakes and Traction Control.
40. Connect the automatic range selector cable to the PNP switch. Refer to Automatic Transmission Range Selector Cable Replacement (At PNP Switch) or Automatic Transmission Range Selector Cable Replacement (At Shift Control) or Automatic Transmission Range Selector Cable Replacement (New Cable Installation) in Transmission and Drivetrain.

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.

41. Connect the throttle and cruise cables with the mounting bracket to the throttle body. Refer to Accelerator Controls Cable Replacement and Accelerator Controls Cable Bracket Replacement in Powertrain Management.
42. Connect the fuel vapor line.





43. Connect the fuel lines to the fuel rail. Refer to Quick Connect Fitting(s) Service (Metal Collar) or Quick Connect Fitting(s) Service (Plastic Collar) in Powertrain Management.
44. Install the engine mount strut to the engine mount strut bracket. Refer to Engine Mount Strut Replacement.





45. Install the throttle body air inlet duct (3). Refer to Air Cleaner Intake Duct Replacement in Powertrain Management.





46. Install the power steering pump to the engine. Refer to Power Steering Pump Replacement in Steering and Suspension.
47. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.
48. Install the drive belt. Refer to Drive Belt Replacement.
49. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging.
50. Fill the cooling system with engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
51. Install the new oil filter and fill the engine with new engine oil. Refer to Engine Oil and Oil Filter Replacement.
52. Inspect all of the fluid levels.
53. Inspect for leaks.