Engine Replacement
Removal ProcedureCaution: Refer to Battery Disconnect Caution in Service Precautions.
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging.
2. Remove the fuel injector sight shield.
3. Drain the engine oil.
4. Drain the engine coolant from the cooling system. Refer to Draining and Filling Cooling System in Cooling System.
5. Remove the diagonal braces. Refer to Brace Replacement - Sheet Metal Diagonal in Body and Frame.
6. Remove the engine mount struts from the engine mount strut brackets. Refer to Engine Mount Strut Replacement (Left) and Engine Mount Strut Replacement (Right).
7. Remove the throttle body air inlet duct and the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Powertrain Management.
8. Remove the washer reservoir bolts and retainers.
9. Remove the underhood accessory wiring junction block. Refer to Junction Block Replacement - Accessory Wiring in Body and Frame.
10. Remove the washer reservoir.
11. Remove the hood. Refer to Hood Replacement in Body and Frame.
12. Disconnect the radiator inlet hose from the engine. Refer to Radiator Hose Replacement - Inlet in Cooling System.
13. Disconnect the radiator outlet hose from the engine. Refer to Radiator Hose Replacement - Outlet in Cooling System.
14. Remove the A/C compressor from the engine. Suitably support the compressor. Refer to Compressor Replacement in Heating and Air Conditioning.
15. Disconnect the starter motor wiring harness.
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.
16. Disconnect the throttle and cruise cables from the bracket. Refer to Accelerator Controls Cable Replacement in Powertrain Management.
17. Remove the wiring harness from the top of the engine.
Important: Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure in Powertrain Management.
18. Disconnect the fuel lines from the fuel rail. Lay the fuel lines aside. Refer to Fuel Hose/Pipes Replacement (Filter to Engine) in Powertrain Management.
19. Disconnect the vacuum lines.
20. Disconnect the heater hoses. Refer to Heater Hoses Replacement in Heating and Air Conditioning.
21. Remove the engine mount strut brackets from the upper radiator support. Refer to Engine Mount Strut Bracket Replacement (Upper Radiator Support).
22. Remove the power steering pump and reposition. Refer to Power Steering Pump Replacement in Steering.
23. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
24. Disconnect the starter motor wiring harness and remove the starter motor.
25. Remove the torque converter cover. Refer to Torque Converter Cover Replacement in Automatic Transaxle - 4T65-E.
26. Remove the engine flywheel-to-torque converter bolts. Refer to Flywheel to Torque Converter Bolts in Automatic Transaxle 4T65-E.
27. Remove the engine mount nuts and bolts. Refer to Engine Mount Replacement.
28. Remove the transaxle brace. Refer to A/T Brace Replacement in Automatic Transaxle - 4T65-E.
29. Remove the three-way catalytic converter pipe from the right (rear) exhaust manifold.
30. Remove the lower transaxle-to-engine bolt (6) and stud (1).
31. Lower the vehicle.
32. Install the engine lifting device.
33. Remove the upper transaxle-to-engine bolts (3, 4, and 5) and stud (2).
34. Remove the engine from the vehicle.
35. Remove the flywheel. Refer to Engine Flywheel Removal (Automatic Transmission).
36. Install the engine to a engine stand.
37. Remove the generator.
38. Remove the ignition control module. Refer to Ignition Control Module Replacement in Powertrain Management.
39. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement
40. Remove the engine mount bracket bolts. Refer to Engine Mount Bracket Replacement.
Installation Procedure
1. Install the engine mount bracket bolts. Refer to Engine Mount Bracket Replacement.
2. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.
3. Install the ignition control module. Refer to Ignition Control Module Replacement in Powertrain Management.
4. Install the generator.
5. Install the flywheel. Refer to Engine Flywheel Removal (Automatic Transmission).
6. Install the engine to the vehicle.
Notice: Refer to Fastener Notice in Service Precautions.
7. Install the upper transaxle-to-engine bolts (3, 4, and 5) and stud (2).
- Tighten the upper transaxle-to-engine bolts (3, 4, and 5) and stud (2) to 75 Nm (55 ft. lbs.).
8. Remove the engine lifting device.
9. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
10. Install the lower transaxle-to-engine bolt (6) and stud (1).
- Tighten the lower transaxle-to-engine bolt (6) and stud (1) to 75 Nm (55 ft. lbs.).
11. Install the three-way catalytic converter pipe to the right (rear) exhaust manifold.
12. Install the transaxle brace. Refer to A/T Brace Replacement in Automatic Transaxle 4T65-E.
13. Install the engine mount lower nuts and bolts. Refer to Engine Mount Replacement.
14. Install the engine flywheel-to-torque converter bolts. Refer to Flywheel to Torque Converter Bolts in Automatic Transmission - 4T65-E.
15. Install the torque converter cover. Refer to Torque Converter Cover Replacement in Automatic Transaxle - 4T65-E.
16. Install the starter motor.
17. Lower the vehicle.
18. Install the power steering pump. Refer to Power Steering Pump Replacement in Steering.
19. Install the engine mount strut brackets to the upper radiator support. Refer to Engine Mount Strut Bracket Replacement (Upper Radiator Support).
20. Install the heater hoses. Refer to Heater Hoses Replacement in Heating and Air Conditioning.
21. Connect the vacuum lines.
22. Install the wiring harness to the engine.
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.
23. Install the throttle and cruise cables to the bracket. Refer to Accelerator Controls Cable Replacement in Powertrain Management.
24. Install the starter motor wiring harness.
25. Install the A/C compressor. Refer to Compressor Replacement in Heating and Air Conditioning.
26. Install the radiator outlet hose to the engine. Refer to Radiator Hose Replacement - Outlet in Cooling System.
27. Install the radiator inlet hose to the engine. Refer to Radiator Hose Replacement - Inlet in Cooling System.
28. Install the throttle body air inlet duct and the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Powertrain Management.
29. Install the hood. Refer to Hood Replacement in Body and Frame.
30. Return the washer reservoir to the proper position.
31. Install the underhood accessory wiring junction block. Refer to Junction Block Replacement - Accessory Wiring in Body and Frame.
32. Install the washer reservoir bolts and retainers.
33. Install the diagonal braces. Refer to Brace Replacement - Sheet Metal Diagonal in Body and Frame.
34. Fill the engine with new engine oil. Refer to Engine Oil and Oil Filter Replacement.
35. Fill the cooling system with engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
36. Install the fuel injector sight shield.
37. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Starting and Charging.