Engine Replacement Automatic Transmission

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Remove the hood. Refer to Hood Replacement in Body Front End.
3. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
4. Evaporate and recover the refrigerant. Refer to Refrigerant Recovery and Recharging in HVAC System--Manual.
5. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls-2.2L.
6. Disconnect the brake booster vacuum line at the intake manifold.

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.
7. Remove the fuel injector rail cover. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls - 2.2L.
8. Remove the accelerator and the cruise control cables from the cable bracket. Refer to Accelerator Control Cable Bracket Replacement in Engine Controls-2.2L.
9. Disconnect the engine wiring harness from the underhood engine components . Refer to Harness Routing Views in Wiring Systems.
10. Remove the cruise control module. Refer to Cruise Control Module Replacement in Cruise Control.
11. Disconnect the A/C line from the accumulator. Refer to Air Conditioning Accumulator Replacement in HVAC System-Manual.
12. Remove the drive belt. Refer to Drive Belt Replacement .
13. Remove the surge tank. Refer to Radiator Surge Tank Replacement in Engine Cooling.
14. Remove the upper and lower radiator hoses. Refer to Radiator Hose Replacement in Engine Cooling.
15. Remove the fuel feed lines at the engine. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls-2.2L.
16. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
17. Remove the coolant pipe assembly. Refer to Engine Coolant Inlet Pipe Replacement in Engine Cooling.
18. Remove the right side wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
19. Remove the right front fender liner. Refer to Front Fender Liner Replacement in Body Front End.
20. Remove the engine mount strut. Refer to Engine Mount Strut Replacement .



21. Remove the flywheel dust cover.
22. Remove the exhaust pipe and hanger from the exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
23. Remove the starter. Refer to Starter Motor Replacement in Engine Electrical.
24. Remove and support the A/C compressor. Refer to Air Conditioning Compressor Replacement in HVAC System-Manual.
25. Remove the A/C compressor bracket. Refer to Compressor Mounting Bracket Replacement in HVAC System-Manual.
26. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .



27. Remove the torque converter bolts.



28. Remove the transmission-to-engine support brace.



29. Remove the lower transmission-to-engine bolts.
30. Lower the vehicle.
31. Support the transmission with a suitable jack.
32. Install the engine lifting device to the engine lifting eyes.



33. Remove the upper front engine mount.



34. Remove the remaining transmission to-engine bolts.
35. Separate the engine from the transmission and lift the engine from the vehicle.

1. Position the engine in the vehicle.



2. Hand-tighten the upper transmission to engine bolts.



3. Install the front upper engine mount.
4. Remove the engine lifting device from the lifting eyes.
5. Remove the jack supporting the transmission.
6. Raise the vehicle.



7. Install the lower transmission-to-engine bolts



8. Install the lower transmission-to-engine brace.



9. Install the torque converter bolts.
10. Install the A/C compressor bracket. Refer to Compressor Mounting Bracket Replacement in HVAC System-Manual.
11. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement in HVAC System-Manual.
12. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.
13. Install the exhaust pipe and hanger to the exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.



14. Install the flywheel dust cover.
15. Install the engine mount strut. Refer to Engine Mount Strut Replacement .
16. Install the right front fender liner. Refer to Front Fender Liner Replacement in Body Front End.
17. Install the right side wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
18. Install the coolant pipe assembly. Refer to Engine Coolant Inlet Pipe Replacement in Engine Cooling.
19. Lower the vehicle.
20. Install the fuel feed lines at the engine. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls-2.2L.
21. Connect the upper and lower radiator hoses. Refer to Radiator Hose Replacement in Engine Cooling.
22. Install the surge tank. Refer to Radiator Surge Tank Replacement in Engine Cooling.
23. Install the fuel rail cover. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls-2.2L.
24. Install the drive belt. Refer to Drive Belt Replacement .
25. Connect the A/C line to the accumulator. Refer to Air Conditioning Accumulator Replacement in HVAC System-Manual.
26. Install the cruise control module. Refer to Cruise Control Module Replacement in Cruise Control.
27. Install the engine wiring harness. Refer to Harness Routing Views in Wiring Systems.

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 and the cruise control cable. Refer to Accelerator Control Cable Bracket Replacement in Engine Controls-2.2L.
29. Connect the brake booster vacuum line at the manifold.
30. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls-2.2L.
31. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
32. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging in HVAC System-Manual.
33. Install the hood. Refer to Hood Replacement in Body Front End.
34. Connect the battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
35. Start the engine and check for leaks.
36. Inspect all of the fluid levels.

Engine Replacement Manual Transmission

Tools Required

J 28467-360 Engine Support Fixture

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure in Engine Controls-2.2L.
3. Drain and recover the coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
4. Remove the air cleaner outlet duct (1). Refer to Air Cleaner Outlet Resonator Replacement in Engine Controls-2.2L.
5. Remove the upper radiator hose at the coolant outlet. Refer to Radiator Hose Replacement in Engine Cooling.



6. Disconnect the brake booster vacuum hose.



7. Disconnect the IAC electrical connection.
8. Disconnect the generator electrical connection. Refer to Generator Replacement in Engine Electrical.



9. Disconnect the throttle position (TPS) sensor electrical sensor.



10. Disconnect the MAP electrical connection.
11. Disconnect the EVAP emission solenoid electrical connection.
12. Disconnect the injector harness electrical connection. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls-2.2L.



13. Disconnect the EGR electrical connection.



14. Disconnect the engine coolant temperature (ECT) sensor electrical connection.



15. Disconnect the Oxygen (O2S) sensor electrical connection.



16. Disconnect the engine grounds electrical connection.
17. Remove the drive belt. Refer to Drive Belt Replacement .
18. Disconnect the transmission shift control cable from the lever and bracket. Refer to Shift Cables in Manual Transmission-M86/M94 Getrag .
19. Remove the coolant surge tank. Refer to Radiator Surge Tank Replacement in Engine Cooling.
20. Disconnect the vacuum line near the master cylinder.
21. Install the engine support fixture. Refer to Engine Support Fixture .
22. Disconnect the lower radiator hose from the coolant pump. Refer to Radiator Hose Replacement in Engine Cooling.
23. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
24. Remove the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
25. Remove both of the front fender liners. Refer to Front Fender Liner Replacement in Body Front End.
26. Remove the exhaust pipe at the exhaust manifold and catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.
27. Remove the engine mount strut. Refer to Engine Mount Strut Replacement .



28. Remove the wheel speed sensor wire harness from the control arms.



29. Separate the ball joints from the steering knuckles. Refer to Lower Control Arm Ball Joint Replacement .
30. Separate the tie rod ends from the struts. Refer to Rack and Pinion Outer Tie Rod End Replacement in Power Steering System.



31. Remove the brake lines from the suspension support below the rack and pinion.
32. Disconnect the A/C compressor electrical connector.
33. Remove the A/C compressor and support with the lines attached. Refer to Air Conditioning Compressor Replacement in HVAC System-Manual.
34. Disconnect the electronic ignition module electrical connection. Refer to Ignition Control Module Replacement in Engine Controls-2.2L.
35. Disconnect the vehicle speed sensor electrical connections. Refer to Ignition Control Module Replacement .
36. Disconnect the cooling fan electrical connection. Refer to Engine Cooling Fan Replacement in Engine Cooling.
37. Disconnect the starter electrical connection. Refer to Starter Motor Replacement in Engine Electrical.
38. Disconnect the oil pressure sensor electrical connector.



39. Disconnect the ground wires.
40. Disconnect the power steering lines from the rack and pinion assembly. Refer to Steering Gear Replacement in Power Steering System.
41. Remove the flexible coupling joint at the rack and pinion assembly. Refer to Steering Gear Replacement in Power Steering System.



42. Remove the following cables from the accelerator control bracket:

•	The accelerator control (2).

•	The cruise control (1).




43. Remove the suspension support center bolts.



44. Remove the suspension support outer bolts.



45. Remove the suspension support upper bolts and the support.
46. Disconnect the heater hoses at the front of the dash. Refer to Heater Hoses Replacement in HVAC System-Manual.
47. Remove both of the drive axles from the transmission and position them aside. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
48. Disconnect the fuel lines. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls-2.2L.
49. Remove the transmission mount thru bolts. Refer to Transmission Front Mount Replacement in Automatic Transaxle-3T40 and Transmission Rear Mount Replacement in Manual Transmission-M86/M94 Getrag.
50. Remove the engine mount assembly. Refer to Engine Mount Replacement .
51. Lower the vehicle until it rests lightly against the support.
52. Remove the J 28467-360 from the engine.
53. Raise the vehicle.
54. Remove the engine from the transmission.

Tools Required

J 28467-360 Engine Support Fixture

1. Install the engine to the transmission.

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.

2. Install the transmission bolts.

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

3. Lower the vehicle onto the engine and transmission assembly.
4. Install the engine support fixture. Refer to Engine Support Fixture .
5. Install the engine mount assembly. Refer to Engine Mount Replacement .
6. Install the transmission mount. Refer to Transmission Front Mount Replacement and Transmission Rear Mount Replacement in Manual Transmission-M86/M94 Getrag.
7. Install both of the drive axles. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
8. Connect the heater hoses. Refer to Heater Hoses Replacement in Heating, Ventilation and Air Conditioning.



9. Install the suspension support upper bolts and the support.



10. Install the suspension support outer bolts.



11. Install the suspension support center bolts.



12. Install the following cables to the accelerator control bracket:

•	The accelerator control (2).

•	The cruise control (1)

13. Install the flexible coupling joint to the rack and pinion assembly. Refer to Steering Gear Replacement in Power Steering System.
14. Connect the power steering lines. Refer to Steering Gear Replacement in Power Steering System.



15. Install the electronic ignition module electrical connection. Refer to Ignition Control Module Replacement in Engine Controls-2.2L.



16. Connect the brake lines to the suspension support.



17. Connect the vehicle speed sensor electrical connections.



18. Connect the cooling fan electrical connection.
19. Connect the starter electrical connection. Refer to Starter Motor Replacement in Engine Electrical.



20. Connect the oil pressure sensor electrical connection.
21. Connect the oil level sensor electrical connection.
22. Connect the grounds electrical connection
23. Connect the oil level sensor electrical connection.
24. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement in HVAC System-Manual.
25. Install the tie rod ends to the struts. Refer to Rack and Pinion Outer Tie Rod End Replacement in Front Suspension.



26. Install the ball joints to the steering knuckles.



27. Install the wheel speed sensor wire harness to the control arms.
28. Install the engine mount strut. Refer to Engine Mount Strut Replacement .
29. Install the exhaust pipe to the exhaust manifold and catalytic converter. Refer to Intermediate Pipe Replacement in Engine Exhaust.
30. Install both of the front fender liners. Refer to Front Fender Liner Replacement in Body Front End.
31. Install the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
32. Lower the vehicle.
33. Connect the lower radiator hose to the coolant pump. Refer to Radiator Hose Replacement .
34. Remove the engine support fixture.
35. Connect the vacuum line near the master cylinder.
36. Install the coolant surge tank. Refer to Radiator Surge Tank Replacement in Engine Cooling.
37. Connect the transmission shift control cables. Refer to Shift Cables .
38. Install the drive belt. Refer to Drive Belt Replacement .



39. Install the IAC electrical connection.
40. Connect the generator electrical connection. Refer to Generator Replacement in Engine Electrical.
41. Connect the throttle position (TPS) sensor electrical connection.





42. Connect the MAP electrical connection.



43. Connect the EVAP emission solenoid electrical connector.



44. Connect the EGR electrical connector.
45. Connect the injector harness. Refer to Fuel Injector Replacement in Engine Controls-2.2L.



46. Connect the engine coolant temperature (ECT) sensor electrical connector.



47. Reconnect the Oxygen (O2S) sensor.



48. Reconnect the engine ground wires.
49. Connect the brake booster vacuum hose.
50. Install the upper radiator hose at the coolant outlet. Refer to Radiator Hose Replacement in Engine Controls-2.2L.
51. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Resonator Replacement in Engine Controls-2.2L.
52. Fill the coolant system. Refer to Cooling System Draining and Filling in Engine Cooling.
53. Refill the engine with oil. Refer to Engine Oil and Oil Filter Replacement .
54. Reconnect the negative battery cable.

Tighten
Tighten the bolt to 16 N·m (12 lb ft).

55. Connect the fuel lines. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls -2.2L.
56. Start the engine and check for leaks.
57. Turn OFF the engine and inspect the fluid levels.