Engine Replacement Manual Transmission

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
3. Evacuate the A/C System. Refer to Refrigerant Recovery and Recharging in Heating, Ventilating, and Air Conditioning.
4. Remove the air cleaner duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls-2.4L.
5. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement in Engine Controls-2.4L.
6. Remove the underhood fuse block.
7. Remove the air cleaner bracket. Refer to Air Cleaner Bracket Replacement in Body Front End.



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 upper engine electrical harness. Refer to Harness Routing Views in Engine Controls.
13. Disconnect the vacuum lines. Refer to Emission Hose Routing Diagram in Engine Controls.
14. Relieve the fuel pressure. Refer to Fuel Pressure Relief in Engine Controls.
15. Disconnect the fuel line quick disconnects. Refer to Metal Collar Quick Connect Fitting Service in Engine Controls.
16. Remove the upper radiator hose. Refer to Radiator Hose Replacement in Engine Cooling.
17. Disconnect the heater hoses from the heater core. Refer to Heater Hoses Replacement in Heating, Ventilating and Air Conditioning.



18. Disconnect the slave cylinder hydraulic line.
19. Remove the EVAP solenoid.
20. Disconnect the ground cables at the rear of the engine block. Refer to Harness Routing Views in Engine Electrical.
21. Remove the power steering pump with lines attached and position the pump out of the way. Refer to Power Steering Pump Replacement in Power Steering Systems.
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 Engine Electrical.
24. Disconnect the surge tank bypass hose from the engine. Refer to Radiator Surge Tank Replacement in Engine Cooling.
25. Disconnect the cruise and accelerator cables from the throttle body. Refer to Accelerator Control Cable Replacement in Engine Controls.
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 and Jacking the Vehicle in General Information.
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 engine splash shields. Refer to Engine Splash Shield Replacement in Body Front End.
33. Remove the front closeout panel fasteners and the panel.
34. Remove the lower radiator support. Refer to Radiator Support Replacement in Collision Repair.
35. Remove the right front brake hose from the vehicle. Refer to Front Brake Hose Replacement in Hydraulic Brakes.
36. Remove the retaining nut from the BPMV at the mounting bracket.



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 Shaft Replacement in Wheel Drive Shafts.
41. Disconnect the ball joints from the control arms. Refer to Lower Control Arm Ball Joint Replacement in Front Suspension.
42. Disconnect the outer tie rod ends from the control arms. Refer to Rack and Pinion Outer Tie Rod End Replacement in Steering.
43. Disconnect the catalytic converter from the exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
44. Remove the A/C compressor hose from the A/C compressor. Refer to Compressor Hose Assembly Replacement in Heating, Ventilating, and Air Conditioning.
45. Remove the bolt from the power steering pressure line retainer. Refer to Power Steering Pressure Pipe/Hose Replacement in Power Steering Systems.
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. Refer to Front Suspension Crossmember Replacement in Front Suspension.
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 thrubolt.



53. Remove the rear transmission mount thrubolt.



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.

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: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

6. Install the two side transmission mount lower nuts.

Tighten
Tighten the transmission mount lower nuts to 44 N·m (60 lb ft).




7. Install the rear transmission mount thrubolt.

Tighten
Tighten the rear transmission mount thrubolt to 55 N·m (75 lb ft).




8. Install the front transmission mount thrubolt.

Tighten
Tighten the front transmission thrubolt to 55 N·m (75 lb ft).

9. Remove the engine hoist 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 Refer to Front Suspension Crossmember Replacement in Front Suspension.
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 Pipe/Hose Replacement in Power Steering Systems.
15. Install the A/C compressor hose to the A/C compressor. Refer to Compressor Hose Assembly Replacement in Heating, Ventilating, and Air Conditioning.
16. Connect the catalytic converter to the exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
17. Connect the outer tie rod ends to the control arms. Refer to Rack and Pinion Outer Tie Rod End Replacement in Steering.
18. Connect the ball joints to the control arms. Refer to Lower Control Arm Ball Joint Replacement in Front Suspension.
19. Install the wheel driveshafts. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.



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.
24. Install the right front brake hose to the vehicle. Refer to Front Brake Hose Replacement in Hydraulic Brakes.
25. Install the lower radiator support. Refer to Radiator Support Replacement in Collision Repair.
26. Install the front closeout panel and the panel fasteners. Ensure the fasteners are retained.
27. Install the engine splash shields. Refer to Engine Splash Shield Replacement in Body Front End.
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 Control Cable Replacement in Engine Controls.
35. Connect the surge tank bypass hose to the engine. Refer to Radiator Surge Tank Replacement in Engine Cooling.
36. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.
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 Power Steering Systems.
39. Connect the ground cables at the rear of the engine block. Refer to Harness Routing Views in Engine Electrical.
40. Install the EVAP solenoid. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement in Engine Controls.



41. Connect the slave cylinder hydraulic line.
42. Connect the heater hoses to the heater core. Refer to Heater Hoses Replacement in Heating, Ventilating, and Air Conditioning.
43. Connect the radiator hoses. Refer to Radiator Hose Replacement in Engine Cooling.
44. Connect the fuel line quick disconnects. Refer to Metal Collar Quick Connect Fitting Service in Engine Controls.
45. Connect the vacuum lines. Refer to Emission Hose Routing Diagram in Engine Controls.
46. Connect the upper engine electrical harness. Refer to Harness Routing Views in Engine Controls.



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. Refer to Air Cleaner Bracket Replacement in Body Front End.
52. Install the underhood fuse block.
53. Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Engine Controls.
54. Install the air cleaner duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls.
55. Charge the A/C system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilating, and Air Conditioning.
56. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
57. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

Engine Replacement Automatic Transmission

Tools Required

1. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
2. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
3. Remove the fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls-2.4L.
4. Disconnect the ignition coil and the module assembly.



5. Disconnect the camshaft position sensor.



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



7. Disconnect the oil pressure sending switch.
8. Remove the cruise control module and set aside. Refer to Cruise Control Module Replacement in Cruise Control.




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. Remove cruise (1) and throttle cables from throttle body.



10. Disconnect the following components:

•	Vacuum line from throttle body

•	MAP sensor (3)

•	IAC sensor (4)

•	Disconnect TPS sensor (2).

11. Disconnect generator electrical.
12. Remove brake booster line from engine.
13. Remove surge tank hose from engine.
14. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
15. Remove the drive belt. Refer to Drive Belt Replacement .
16. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
17. Remove the starter. Refer to Starter Motor Replacement in Engine Electrical.



18. Disconnect the exhaust pipe from the exhaust manifold.
19. Remove the torque converter bolts. Refer to Transmission Replacement in Automatic Transaxle-4T40-E/4T45-E.
20. Remove the A/C compressor bolts. Position the compressor out of the way. Refer to Air Conditioning Compressor Replacement in HVAC.
21. Remove the lower oil pan to bell housing bolts.
22. Remove lower radiator hose from engine.
23. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
24. Remove the transmission mount. Refer to Transmission Mount Replacement - Side in Automatic Transaxle-4T40-E/4T45-E.
25. Remove upper radiator hose from engine.
26. Remove the upper transmission to engine bolts.
27. Install the engine lifting device. Support the transaxle.
28. Remove engine mount. Refer to Engine Mount Replacement .
29. Raise the engine slightly to separate the engine from the transaxle and remove from vehicle.



30. Remove the flywheel bolts and the flywheel.
31. Mount the engine on a suitable engine stand.

1. Remove engine from stand.
2. Use the J 38122-A to hold the balancer while tightening the flywheel bolts

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the flywheel, the retainer and the bolts.

Tighten
Tighten bolts to 30 N·m (22 lb ft). Then turn all bolts an additional 45 degrees.

4. Attach the engine lifting device to the engine.
5. Install the engine into the vehicle and align the transaxle to the engine.
6. Install the upper transmission to engine bolts.

Tighten
Tighten bolts to 75 N·m (55 lb ft).

7. Install the engine mount and the mount bracket. Refer to Engine Mount Replacement .
8. Remove engine hoist.
9. Install upper radiator hose to engine.
10. Install the transaxle mount. Refer to Transmission Front Mount Replacement in Automatic Transaxle-4T40-E/4T45-E.
11. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
12. Install the lower radiator hose to engine.
13. Install lower engine to transmission bolts.

Tighten
Tighten bolts to 75 N·m (55 lb ft).

14. Install A/C compressor. Refer to Air Conditioning Compressor Replacement in HVAC.
15. Install the torque converter bolts. Refer to Transmission Replacement in Automatic Transaxle-4T40-E/4T45-E.



16. Connect the exhaust pipe.
17. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.
18. Install the transaxle brace. Refer to Transmission Replacement in Automatic Transaxle-4T40-E/4T45-E.
19. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
20. Install the drive belt. Refer to Drive Belt Replacement .
21. Install the engine splash shield. Refer to Engine Splash Shield Replacement in Body Front End.
22. Install the front wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
23. Lower the vehicle.
24. Install surge tank hose.
25. Install brake booster vacuum line.
26. Connect generator electrical.



27. Connect the following electrical connectors:

•	The MAP sensor (3)

•	The IAT sensor (4)

•	The evaporator canister (1)

•	The EGR sensor





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.
28. Install the accelerator cable (1) and bracket.
29. Install the cruise control assembly. Refer to Cruise Control Module Replacement in Cruise Control.



30. Connect the oil pressure switch.



31. Install the power steering pump.



32. Connect the camshaft position sensor.
33. Connect the ignition coil and module.
34. Install the fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls-2.4L.
35. Install the air intake assembly. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls-2.4L.
36. Refill the engine oil. Refer to Engine Oil and Oil Filter Replacement .
37. Refill the engine cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
38. Run the engine to operating temperature and retest all fluid levels.