Engine Replacement Manual Transmission

Tools Required

1. Remove the steering gear-to-intermediate shaft pinch bolt. Access is from the inside of the vehicle at the front of the dash.
2. Remove the battery.
3. Disconnect the main wire feed to the fuse block.
4. Disconnect the main ground on the left fender well.
5. Remove the intake air temperature (IAT) electrical connector.
6. Remove the air cleaner lid and the inlet duct.
7. Remove the air box.
8. Disconnect the purge hose from the throttle body and route away from the engine.
9. Disconnect the following electrical connections:

9.1.	The purge solenoid

9.2.	The rear HO2S sensor

9.3.	The main harness connector by the master cylinder

9.4.	The transaxle back-up switch

10. Remove the front-of-dash cover.
11. Remove the PCM boot from the front of the dash.
12. Disconnect the PCM electrical connectors and secure to the engine.
13. Remove the fuse block.
14. Disconnect the engine harness main connector from the bottom of the fuse block.
15. Remove the battery tray and the fuse block tray.
16. Remove the cruise control and throttle cables.
17. Disconnect the brake assist vacuum line from the throttle body and route away from the engine.
18. Loosen the pinch bolt securing the control assembly rod to the control shaft lever assembly.

Notice: The control shaft lever retaining pin has a spring loaded locking feature securing the pin in place. If this spring is not depressed before attempting to remove the pin, damage to the pin will result.

19. Remove the pin retaining control shaft lever to shift control shaft of the transaxle.
20. Remove the retaining clips holding the control shaft lever assembly to the transaxle and frame assembly brackets.
21. Remove the control shaft lever assembly by pulling straight up from the pivot pins.
22. Drain the coolant.
23. Remove the heater hoses from the front of the dash.
24. Remove the upper and lower radiator hoses from the radiator.
25. Relieve the fuel pressure. Refer to Fuel Pressure Relief in Engine Controls-2.2L (L61).
26. Disconnect the fuel lines.
27. Secure the radiator to the upper radiator support.

Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

28. Raise the vehicle on a hoist.
29. Remove both of the front wheels.
30. Remove the right front splash shield.
31. Remove the left front wheel liner push pin from the frame.
32. Install wood blocks between the transaxle case and frame.
33. Install wood blocks between the crank pulley and frame.
34. Lower the vehicle.
35. Disconnect the right engine and left transaxle mounts by removing the mount assembly-to-engine/transaxle bolts. The mount brackets will remain on the engine and transaxle.
36. Disconnect the rear oxygen sensor harness from the frame at the 2 attachment points.
37. Remove the exhaust manifold pipe from the catalytic converter forward.
38. Remove the A/C line to frame attachment clip at the front of the frame.

Important: It is not necessary to disconnect the A/C lines.

39. Remove the A/C compressor from the engine and secure to the cooling module.
40. Remove the tie rod-to-steering knuckle bolts and separate the tie rod from the steering knuckle assembly. Discard the tie rod bolts.
41. Remove the stabilizer bar links from the strut assembly.

Notice: Do not attempt to separate the joint using a wedge-type tool because seal may be damaged.

42. Remove the lower ball stud bolt and separate the ball from the steering knuckle assembly.
43. Remove the suspension support assemblies.
44. Remove the suspension support cage nuts from the body. Discard the cage nuts.
45. Support the powertrain and frame with the powertrain lifting table and the J 43628 .
46. Remove the remaining 4 frame-to-body attachment fasteners.
47. Carefully lower the powertrain and frame assembly from the vehicle.
48. Remove the remaining 4 cage nuts and discard.

1. Install the new cage nuts into the body as torque retention of the old nuts may not be sufficient.

Important: Ensure that the J 43628 fully engages into all alignment holes.

2. Carefully raise the powertrain into the vehicle.

Important: Do not tighten the fasteners at this time.

3. Install the 4 new frame-to-body bolts.
4. Install the suspension supports using the new bolt and tighten all of the frame bolts.

Tighten
Tighten the suspension support bolts to 100 N·m (74 lb ft).

5. Install the ball stud into the steering knuckle. Use the new ball stud nut.

Tighten
Tighten the ball stud-to-steering knuckle nuts to 100 N·m (74 lb ft).

6. Install the stabilizer link-to-strut assembly.

Tighten
Tighten the stabilizer link-to-strut assembly to 65 N·m (50 lb ft).

Important: Use a new tie rod nut. The torque retention of the old nut may not be sufficient.

7. Install the tie rod into the steering knuckle.
8. Using the J 44015 , or equivalent, seat the tie rod end into the knuckle and tighten again.

Tighten
Tighten the tie rod end linkage installer to 45 N·m (35 lb ft).

9. Remove the linkage installer and install the new tie rod nut and tighten.

Tighten
Tighten the tie rod nut to 60 N·m (45 lb ft).

10. Install the exhaust manifold pipe.
11. Install the A/C compressor-to-engine mounting bolts.

Tighten
Tighten the A/C compressor-to-block bolt to 25 N·m (18 lb ft).

12. Install the A/C line-to-frame attachment clip at the front of the frame.
13. Route the rear oxygen sensor harness and attach to the attachment points.
14. Install the right engine mount bolts and install the left transaxle mount bolts.

Tighten

•	Tighten the engine mount-to-engine mount bracket bolts to 55 N·m (41 lb ft).

•	Tighten the transaxle mount bolts to 55 N·m (41 lb ft).

Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

15. Raise the vehicle.
16. Remove the wood blocks from the crank pulley and transaxle case.
17. Install the left front wheel liner push pin from the frame.
18. Install the right front splash shield.
19. Install both of the front wheels.
20. Lower the vehicle.
21. Remove the radiator from the upper radiator support.
22. Connect the fuel lines. Use new fuel line retainer clips.
23. Install the upper and lower radiator hoses from the radiator.
24. Install the heater hose.
25. Connect the brake assist vacuum lines to the brake booster.
26. Install and adjust the shift control rod as follows:

26.1.

Install the shift rod into the shift linkage assembly.

26.2.

Rotate the transaxle shift control shaft clockwise, toward the passenger side of the vehicle, and depress the spring loaded transaxle shift linkage lock pin on the transaxle case.

26.3.

Pull up the shift lever boot.

26.4.

Move the shift lever to 5th (reverse gate) using a 3/8 in. punch to hold in place.

26.5.

Tighten the pinch bolt.

Tighten
Tighten the shift control rod pinch bolt to 12 N·m (9 lb ft) plus 180 degrees.

27. Attach the cruise control and throttle cables.
28. Install the battery tray and fuse block tray.
29. Connect the engine harness main connector on the bottom of the fuse block.
30. Install the fuse block.
31. Connect the PCM electrical connectors.
32. Install the PCM boot under the front-of-dash cover.
33. Install the front-of-dash cover.
34. Connect the following connections:

•	The purge solenoid

•	The rear oxygen sensor

•	The main harness connector by the master cylinder

•	The transaxle back-up switch

35. Connect the purge hose to the throttle body.
36. Install the air cleaner box.
37. Install the air cleaner lid and the inlet duct.
38. Connect the intake air temperature (IAT) electrical connection.
39. Connect the main ground on the left fender well.
40. Connect the main wire feed to the fuse block.
41. Install the battery.
42. Connect the steering gear-to-intermediate shaft pinch bolt and tighten.

Tighten
Tighten the steering gear-to-intermediate shaft pinch bolt to 30 N·m (22 lb ft).

43. Refill the coolant tank.
44. Add power steering fluid.

Engine Replacement Automatic Transmission

1. Remove the battery.
2. Disconnect the main wire feed to the fuse block.
3. Disconnect the main ground on the left fender well.
4. Remove the intake air temperature (IAT) electrical connection.
5. Remove the air cleaner lid and the inlet duct.
6. Remove the air box.
7. Disconnect the purge hose from the throttle body and route away from the engine.
8. Disconnect the following electrical connections:

•	The purge solenoid electrical

•	The rear HO2S sensor

•	The main harness connector near the master cylinder

•	The generator

•	The A/C pressure switch

•	The transmission (3 connectors)

•	The right front speed sensor (disconnect and pull through the fender well)

9. Remove the cowl cover.
10. Remove the PCM boot from the cowl.
11. Disconnect the PCM electrical connectors and secure to the engine.
12. Remove the fuse block lid.
13. Disconnect the engine harness connectors from the fuse block.
14. Remove the battery tray and fuse block tray.
15. Disconnect the cruise control and throttle cables.
16. Remove the coolant reservoir cap.
17. Disconnect the brake assist vacuum line from the throttle body and route away from the engine.
18. Relieve the fuel pressure. Refer to Fuel Pressure Relief in Engine Controls-2.2L (L61).
19. Disconnect the fuel lines and secure away from the engine.
20. Disconnect the EVAP purge hose at the EVAP purge solenoid.

Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

21. Raise the vehicle.
22. Drain the engine coolant.
23. Remove the starter.
24. Remove the torque converter bolts.
25. Remove the exhaust system from the catalytic converter forward.
26. Disconnect the transmission nose bracket.
27. Remove the A/C compressor mounting bolts and secure to the frame rail.

Important: It is not necessary to disconnect the A/C lines.

28. Disconnect the lower engine to transmission bell housing bolts. Do not remove the upper bolts at this time.
29. Lower the vehicle.
30. Disconnect the heater hoses at the lower cowl.
31. Remove the main hose to the coolant reservoir from the engine inlet adapter.
32. Remove the lower radiator hose from the engine.
33. Remove the upper radiator hose from the engine.
34. Drain the power steering fluid by removing the smaller hose from under the reservoir.
35. Disconnect the metal power steering line.
36. Attach the engine lift hoist to the lift hooks on the engine and support the engine weight.
37. Support the weight of the transaxle with the floor jack or jack stand.
38. Remove the right front engine mount from the wheel housing.
39. Remove the engine mount bracket from the engine.
40. Remove the upper bell housing bolts.
41. Lift the engine out of the vehicle.

1. Support the transaxle with the floor jack or jack stand.
2. Lower the engine into the vehicle and guide to mate with the dowel pins on the transmission.
3. When the engine and transmission are aligned on the shuffle pins, install the upper bell housing bolts. Do not torque at this time.

Notice: Refer to Fastener Notice in the Preface section.

4. Install the engine mount bracket onto the engine and install the bolts.

Tighten
Tighten the engine mount bracket-to-engine bolts to 90 N·m (66 lb ft).

5. Install the right front engine mount and install the bolts.

Tighten
Tighten the engine mount-to-body bolts to 55 N·m (41 lb ft).

6. Install the transmission nose bracket bolts.

Tighten
Tighten the transmission nose bracket bolts to 35 N·m (26 lb ft).

7. Remove the engine lift hoist.
8. Attach the metal power steering line.
9. Attach the lower power steering hose to the bottom of the power steering reservoir.
10. Install the upper radiator hose.
11. Install the lower radiator hose.
12. Attach the main coolant reservoir hose to the engine.

Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

13. Raise the vehicle.
14. Install the lower engine to transmission bell housing bolts and tighten.

Tighten
Tighten the lower engine-to-transmission bell housing bolts to 65 N·m (48 lb ft).

15. Install the torque convertor bolts.

Tighten
Tighten the torque convertor bolts to 45 N·m (33 lb ft).

16. Install the starter.
17. Connect the heater hoses at the lower cowl.
18. Install the A/C compressor to engine mounting bolts.

Tighten
Tighten the A/C compressor-to-block bolts to 25 N·m (18 lb ft).

19. Install the accessory drive belt.
20. Install the exhaust down pipes to the catalytic convertor.
21. Lower the vehicle.
22. Tighten the upper bell housing bolts.

Tighten
Tighten the upper bell housing bolts to 65 N·m (48 lb ft).

23. Connect the EVAP purge solenoid and EVAP purge hose.
24. Connect the fuel lines.
25. Connect the brake assist vacuum hose.
26. Install the cruise control and throttle cables.
27. Install the battery tray and fuse block tray.
28. Install the fuse block.

28.1.

Install the fuse block mounting bolts.

28.2.

Route the engine harness into the fuse block.

28.3.

Connect the lower weather pack connector.

28.4.

Connect the main engine harness under the fuse block panel.

28.5.

Assemble the fuse block and install the fuse block cover.

29. Connect the PCM electrical connector.
30. Install the PCM boot to the cowl.
31. Install the cowl cover.
32. Connect the following electrical connections:

32.1.

The main harness connector by the master cylinder

32.2.

The rear HO2S sensor

32.3.

The purge solenoid electrical

33. Connect the purge hose to the throttle body.
34. Install the air box.
35. Install the air cleaner lid and the inlet duct.
36. Install the intake air temperature (IAT) electrical connection.
37. Connect the main ground on the left fender wall.
38. Connect the main wire feed to the fuse block.
39. Install the battery.
40. Add coolant.
41. Add power steering fluid.
42. Start the engine and check for leaks.