Engine Replacement (Except South America)

Engine Replacement (Except South America)

Special Tools

* BO-38185 - Hose Clamp Pliers

* J-39580 - Engine Support Table.

For equivalent regional tools, refer to Special Tools Special Tools.

Removal Procedure

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.

2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging.

3. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (GE 47716) Cooling System Draining and Filling (GE 47716).

4. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement Service and Repair





5. Remove the air cleaner outlet duct (1). Refer to Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement.





6. Remove the air cleaner assembly (1). Refer to Air Cleaner Assembly Replacement Service and Repair.





7. Remove the oil cap (1).

8. Remove the intake manifold cover (2).





9. Relieve the system pressure. Refer to Fuel Pressure Relief Service and Repair

10. Disconnect the fuel feed line (1).





11. Disconnect the EVAP pipe (1). Refer to Plastic Collar Quick Connect Fitting Service Procedures.





12. Disconnect heater inlet hose (1). Refer to Heater Inlet Hose Replacement (LEA) Heater Inlet Hose ReplacementHeater Inlet Hose Replacement (LFW) Heater Inlet Hose Replacement.

13. Disconnect heater outlet hose (2). Refer to Heater Outlet Hose Replacement (LFW) Heater Outlet Hose ReplacementHeater Outlet Hose Replacement (LEA) Heater Outlet Hose Replacement.

14. Remove the radiator surge tank. Refer to Radiator Surge Tank Replacement Radiator Surge Tank Replacement.





15. Remove the A/C compressor hose to evaporator outlet hose nut (1).

16. Disconnect the A/C compressor hose to evaporator outlet hose (2). Refer to Air Conditioning Compressor Hose Replacement (V6) Air Conditioning Compressor Hose Replacement (V6)Air Conditioning Compressor Hose Replacement (L4) Air Conditioning Compressor Hose Replacement (L4).

17. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair

18. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement (Base) Bumper.





19. Use paint in order to place match marks on the steering shaft coupling and on the steering column shaft.

20. Remove the steering shaft coupling bolt (1) at the steering column. Refer to Steering Shaft Coupling Replacement (NVH) Service and Repair





21. Remove the exhaust muffler nuts (1) and gasket (2) from the catalytic converter. Refer to Catalytic Converter Replacement (LEA) Catalytic Converter Replacement.





22. Remove the steering linkage outer tie rod nut (1) and tie rod (2). Refer to Steering Linkage Outer Tie Rod Replacement Steering Linkage Outer Tie Rod Replacement.





Note:
Do not allow the stabilizer link ball stud to rotate while removing the link nut.

23. Remove the nut (1) and separate the stabilizer link from the strut assembly. Refer to Steering Knuckle Replacement Service and Repair.





24. Remove the steering knuckle to strut bolts (1) and nuts (2). Refer to Strut Assembly Removal and Installation Strut Assembly Removal and Installation.

25. Remove the starter. Refer to Starter Replacement (LFW) Service and RepairStarter Replacement (LEA) Service and Repair





26. Mark the relationship of the flywheel to the torque converter for reassembly.

27. Remove the torque converter to flywheel bolt (1).





28. Remove the lower transmission bolts (1).

Note:
Blocks of wood can be used between the front of the frame and the oil pan to table in order to level the powertrain during the removal.

29. Position a engine support table under the powertrain assembly.





30. Remove the frame bolts (1).

31. Lower the vehicle on the engine support table.





32. Remove the headlamp bolts (1).

33. Remove the radiator bolts (2).





34. Remove the transmission mount bolts (1).





35. Remove the engine mount bolts (1).

36. Disconnect electoral connector as necessary.

37. Disconnect coolant hoses as necessary.

Note:
When lowering the engine/transaxle assembly, verify all brake lines, shiftier cables and other components are free during removal.

38. Lower the engine table and raise the body on the hoist until the engine/transaxle and cradle are free from the vehicle





39. Remove the transmission brace (1).





40. Remove the lower trans bolts (1)





41. Remove the upper transmission bolts (1)

42. Separate the engine from the transmission.

43. Install the engine to a suitable engine stand.

Installation Procedure

1. Remove the engine from the engine stand.

2. Install the transmission to the engine.





Caution:
Refer to Fastener Caution Fastener Caution.

3. Install the upper transmission bolts (1) and tighten to 75 Nm(55 lb ft).





4. Install the upper transmission bolts (1) and tighten to 75 Nm(55 lb ft).





5. Install the transmission brace (1) and tighten to 58 Nm(43 lb ft).

6. Slowly lower the body onto the powertrain.





7. Install the NEW left transmission mount to transmission bolts (1) and tighten to 50 Nm(37 lb ft).





8. Install the NEW right side engine mount bolts (1) and tighten to 58 Nm(43 lb ft).





9. Install radiator support bolts (2) and tighten to 22 Nm(16 lb ft).

10. install headlamp bolts (1) and tighten 8 Nm(66 lb in).

11. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.





12. Install the frame bolts (1) and tighten to 155 Nm(114 lb ft).

13. Install frame reinforcement bolts (1) and tighten to 100 Nm(74 lb ft).





14. Install the lower transmission bolts (1) and tighten to 75 Nm(55 lb ft).





15. Install the torque converter to flywheel bolts (1) and tighten to 62 Nm(46 lb ft).

16. Install the starter. Refer to Starter Replacement (LFW) Service and RepairStarter Replacement (LEA) Service and Repair.





17. Align the match marks and connect the steering shaft coupling to the steering column.

18. Install the NEW steering shaft coupling bolt (1) at the steering column and tighten to 30 Nm(22 lb ft).





19. Install the NEW strut to the steering knuckle using new bolts (1) and nuts (2) and tighten to 185 Nm(136 lb ft).

20. Inspect the stabilizer link seals for damage and replace the link as necessary.





Note:
Use the proper size allen wrench to keep the stabilizer link ball stud from rotate while installing the nut

21. Install the stabilizer link to the strut nut (1) and tighten to 65 Nm(48 lb ft).





22. Install the steering linkage outer tie rod (2). Refer to Steering Linkage Outer Tie Rod Replacement Steering Linkage Outer Tie Rod Replacement.

23. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement (Base) Bumper.





24. Install A/C compressor hose to evaporator outlet hose (2). Refer to Air Conditioning Compressor Hose Replacement (V6) Air Conditioning Compressor Hose Replacement (V6)Air Conditioning Compressor Hose Replacement (L4) Air Conditioning Compressor Hose Replacement (L4).





25. Connect heater inlet hose (1). Refer to Heater Inlet Hose Replacement (LEA) Heater Inlet Hose ReplacementHeater Inlet Hose Replacement (LFW) Heater Inlet Hose Replacement.

26. Connect heater outlet hose (2). Refer to Heater Outlet Hose Replacement (LFW) Heater Outlet Hose ReplacementHeater Outlet Hose Replacement (LEA) Heater Outlet Hose Replacement.

27. Install the radiator surge tank. Refer to Radiator Surge Tank Replacement Radiator Surge Tank Replacement





28. Connect the EVAP pipe (1). Refer to Plastic Collar Quick Connect Fitting Service Procedures.





29. Install the fuel feed line (1).





30. Install intake manifold cover (2).

31. install the oil cap (1).





32. Install the air cleaner assembly (1). Refer to Air Cleaner Assembly Replacement Service and Repair.





33. Install the air cleaner outlet duct (1). Refer to Air Cleaner Outlet Duct Replacement Air Cleaner Outlet Duct Replacement.

34. Fill the engine oil. Refer to Engine Oil and Oil Filter Replacement Service and Repair.

35. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (GE 47716) Cooling System Draining and Filling (GE 47716).

36. charge the refrigerant system. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging.

37. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection