Engine Replacement

Engine Replacement

Removal Procedure

1. With the tires in the straight forward position, remove the key from the ignition.
2. Disconnect the negative battery cable.
3. Remove the air outlet duct.




4. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.




5. Disconnect the fuel line from the fuel rail.
6. Remove the supercharger.
7. Remove the surge tank to cylinder head pipe.
8. Remove the radiator outlet hose.




9. Remove the inlet (1) and outlet (2) heater hoses.




10. Disconnect the following harness connectors:
^ TMAP sensor
^ Electronic temperature control (ETC)
^ Manifold absolute pressure (MAP) sensor
^ Barometric pressure (BARO) sensor
^ Crankshaft sensor
^ Oil pressure sensor
^ Purge solenoid
^ Ignition coil modules
^ Oxygen (O2) sensor
^ Vehicle speed sensor
^ Engine temperature sensor
^ Boost solenoid
^ Back up lamp switch
11. Disconnect the charge air cooler hoses.
12. Raise and suitably support the vehicle.
13. Recover the refrigerant.




14. Disconnect the starter harness connectors (3, 4, 5).
15. Disconnect the generator harness connectors.
16. Drain the engine oil.
17. Disconnect the front exhaust pipe from the exhaust manifold.
18. Disconnect the transmission shift cable from the transmission.
19. Use blocks of wood to support the powertrain assembly between the frame and the powertrain.




20. Disconnect the drive axles from the steering knuckle.
21. Attach the engine lift hoist to the engine lift hooks.




22. Remove the starter.
23. Remove the transmission to engine bolts.
24. Separate the engine from the transmission.
25. Remove the clutch pressure plate and disk.
26. Remove the following components:
^ Exhaust manifold
^ Exhaust manifold studs
^ Engine mount bracket
^ Fuel rail
^ Thermostat housing and feed pipe
^ Generator

Installation Procedure

1. Attach the engine lift hoist to the engine lift hooks.
2. Install the following components:
^ Exhaust manifold-Refer to Exhaust Manifold Replacement (RPO L61) Exhaust Manifold Replacement (RPO LE5) Exhaust Manifold Replacement (RPO LSJ).
^ Engine mount bracket-Refer to Engine Mount Bracket Replacement
^ Fuel rail-Refer to Fuel Rail Assembly Replacement.
^ Idler pulley
^ Drive belt tensioner-Refer to Drive Belt Tensioner Replacement - Supercharger
^ Thermostat housing and feed pipe-Refer to Thermostat Replacement (RPO L61) Thermostat Replacement (RPO LE5) Thermostat Replacement (RPO LSJ) in Engine Cooling.
^ Generator-Refer to Generator Replacement (RPO LSJ) Generator Replacement (RPOs L61/LE5)
^ Flywheel-Refer to Engine Flywheel Replacement
^ Clutch pressure plate and disk-Refer to Clutch Drive Plate and Clutch Driven Plate (M86) Clutch Drive Plate and Clutch Driven Plate (MU3) in Clutch.
3. Align the engine to the transmission.





Notice: Refer to Fastener Notice.

4. Secure the engine to the transmission.

Tighten the transmission to engine bolts to 75 N.m (55 lb ft).




5. Install the starter.




6. Connect the drive axles to the steering knuckles.
7. Remove the wood blocks between the powertrain and frame.
8. Connect the transmission shift cable to the transmission.




9. Connect the exhaust takedown pipe to the exhaust manifold.

Tighten the nuts to 30 N.m (22 lb ft).

10. Connect the generator harness connectors.

Tighten the generator terminal nut to 20 N.m (15 lb ft).




11. Connect the starter harness connectors (3, 4, 5).
^ Tighten the battery terminal nut to 17 N.m (13 lb ft).
^ Tighten the S-terminal nut to 3 N.m (27 lb in).
12. Install the supercharger.
13. Connect the charge air cooler hoses.
14. Connect the following harness connectors:
^ TMAP sensor
^ ETC
^ MAP sensor
^ Crankshaft sensor
^ Oil pressure sensor
^ Purge solenoid
^ BARO sensor
^ Ignition coil modules
^ O2 sensor
^ Vehicle speed sensor
^ Engine temperature sensor
^ Boost solenoid




15. Install the inlet heater hose (1) and outlet heater hose (2).




16. Connect the fuel line to the fuel rail.
17. Install the surge tank to the cylinder head pipe.

Tighten the bolt to 10 N.m (89 lb in).




18. Release the cooling module from the upper body structure.
19. Install the air outlet duct
20. Connect the negative battery cable.
21. Fill the engine with engine oil to the proper level.
22. Fill the cooling system.
23. Road test the vehicle.