Engine Replacement Auto Transmission

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
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. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging in HVAC Systems-Manual.
5. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls-2.4L.
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 accelerator and the cruise control cables from the cable bracket. Refer to Accelerator Control Cable Bracket Replacement in Engine Controls-2.4L.
8. Disconnect the engine wiring harness from the underhood engine components.
9. Remove the cruise control module. Refer to Cruise Control Module Replacement in Cruise Control.
10. Disconnect the A/C line from the accumulator. Refer to Air Conditioning Accumulator Replacement in HVAC Systems-Manual.
11. Remove the drive belt. Refer to Drive Belt Replacement .
12. Remove the surge tank. Refer to Radiator Surge Tank Replacement in Engine Cooling.
13. Remove the upper and lower radiator hoses. Refer to Radiator Hose Replacement in Engine Cooling.
14. Remove heater hoses. Refer to Heater Hoses Replacement in HVAC Systems-Manual.
15. Remove power steering pump. Refer to Power Steering Pump Replacement in Power Steering System.
16. Remove the fuel rail from the engine. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls.
17. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
18. Remove the radiator outlet pipe assembly. Refer to Radiator Outlet Pipe Replacement in Engine Cooling.
19. Remove the right side wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
20. Remove the right engine splash shield. Refer to Engine Splash Shield Replacement in Body Front End.
21. Remove the engine mount strut. Refer to Engine Mount Strut Replacement .
22. Remove the flywheel inspection shield.
23. Remove the catalytic converter from manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
24. Remove the starter. Refer to Starter Motor Replacement in Engine Electrical.
25. Remove and support the A/C compressor. Refer to Air Conditioning Compressor Replacement in HVAC Systems-Manual.
26. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .



27. Remove the torque converter bolts.



28. Remove the lower transmission-to-engine bolts.
29. Remove crankshaft balancer. Refer to Crankshaft Balancer Replacement .
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. Refer to Engine Mount Replacement .



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. Refer to Engine Mount Replacement .
4. Remove the engine lifting device from the lifting eyes.
5. Remove the jack supporting the transmission.
6. Raise the vehicle.
7. Install crankshaft balancer. Refer to Crankshaft Balancer Replacement .



8. Install the lower transmission-to-engine bolts



9. Install the torque converter bolts.
10. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement in HVAC Systems-Manual.
11. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.
12. Install the catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.
13. Install the flywheel inspection shield.
14. Install the engine mount strut. Refer to Engine Mount Strut Replacement .
15. Install the right engine splash shield. Refer to Engine Splash Shield Replacement in Body Front End.
16. Install the right side wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
17. Install the radiator pipe assembly. Refer to Radiator Outlet Pipe Replacement in Engine Cooling.
18. Lower the vehicle.
19. Install the fuel rail to engine. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls.
20. Connect the upper and lower radiator hoses. Refer to Radiator Hose Replacement in Engine Cooling.
21. Install heater hoses to engine. Refer to Heater Hoses Replacement in HVAC Systems-Manual.
22. Install the surge tank. Refer to Radiator Surge Tank Replacement in Engine Cooling.
23. Install power steering pump. Refer to Power Steering Pump Replacement in Power Steering System.
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 Systems-Manual.
26. Install the cruise control module. Refer to Cruise Control Module Replacement in Cruise Control.
27. Install the engine 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.
28. Install the accelerator and the cruise control cable. Refer to Accelerator Control Cable Bracket Replacement in Engine Controls-2.4L.
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-2.4L.
31. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
32. Fill engine oil. Refer to Engine Oil and Oil Filter Replacement .
33. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging in HVAC Systems-Manual.
34. Install the hood. Refer to Hood Replacement in Body Front End.
35. Connect the battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
36. Start the engine and check for leaks.
37. Check 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 in Engine Electrical.
2. Drain cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
3. Recover the refrigerant if equipped with A/C. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.
4. Disconnect the heater hose at the thermostat housing.
5. Disconnect the radiator inlet (upper) hose. Refer to Radiator Hose Replacement in Engine Cooling.
6. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls-2.4L.
7. Remove the cooling fan. Refer to Engine Cooling Fan Replacement in Engine Cooling.
8. Remove the compressor/condenser hose assembly at the compressor and discard the O-rings, if the vehicle is A/C equipped. Refer to Compressor Hose Assembly Replacement in Heating, Ventilation and Air Conditioning.
9. Disconnect the vacuum hoses from the front of the engine.



10. Remove the generator electrical connection.
11. Remove the A/C compressor electrical connection, if equipped.



12. Remove the injector harness electrical connection.



13. Remove the IAC sensor electrical connection at the throttle body.



14. Remove the TP sensor electrical connection at the throttle body.



15. Remove the MAP sensor electrical connection.
16. Remove the EVAP Canister Purge solenoid electrical connection.



17. Remove the ground connections.



18. Remove the negative battery cable from the transmission.



19. Remove the electronic ignition coil and module assembly electrical connection.



20. Remove the engine coolant temperature sensor electrical connection.



21. Remove the oil pressure sensor/switch electrical connection.



22. Remove the O2S (Oxygen sensor) electrical connection.
23. Remove the crankshaft position sensor.
24. Remove the back up lamp switch electrical connection and position the harness aside.



25. Remove the camshaft position sensor electrical connection.
26. Remove the power brake vacuum hose from the throttle body.



27. Remove the following components:

•	The accelerator control cable (1)

•	The cruise control cable (2)

28. Remove the power steering bolts.



29. Remove the power steering pump. Position the pump aside with the lines attached. Refer to Power Steering Pump Replacement in Power Steering System.

Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.

30. Disconnect the fuel lines. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls-2.4L.



31. Remove the shift control housing and position aside.



32. Disconnect the clutch actuator line.
33. Remove the exhaust manifold and heat shield. Refer to Exhaust Manifold Replacement in Engine Exhaust.
34. Disconnect the radiator outlet (lower) hose from the radiator. Refer to Radiator Hose Replacement in Engine Cooling.
35. Install the J 28467-360 .
36. Remove the surge tank. Position the tank aside with the hoses connected. Refer to Radiator Surge Tank Replacement in Engine Cooling.
37. Remove the engine mount assembly. Refer to Engine Mount Replacement .
38. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
39. Remove the front wheel and tire assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
40. Remove the right engine splash shield. Refer to Engine Splash Shield Replacement in Body Front End.



41. Remove the VSS electrical connection.
42. Remove the knock sensor electrical connection.
43. Remove the starter. Refer to Starter Motor Replacement in Engine Electrical.
44. Remove the both of the front ABS wheel speed sensor electrical connections.
45. Remove the engine mount strut. Refer to Engine Mount Strut Replacement .



46. Unroute the ABS wheel speed sensor.



47. Remove the transmission mount. Refer to Transmission Front Mount Replacement and Transmission Rear Mount Replacement in Manual Transmission-M86//M94 Getrag.
48. Separate the ball joints from the steering knuckles. Refer to Lower Control Arm Ball Joint Replacement in Front Suspension.



49. Remove the suspension support upper bolts.



50. Remove the suspension support lower bolts.



51. Remove the suspension support center bolts and the support.
52. Disconnect the heater outlet hose from the radiator outlet pipe.
53. Remove the wheel drive shaft from the transmission and intermediate shaft (manual transmission only). Position the axle shaft aside. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.



54. Remove the flywheel housing cover.
55. Position suitable support below the engine and lower the car into the support.
56. Mark the threads on the support fixture hooks in order to duplicate the setting when reinstalling the engine.
57. Remove the engine support fixture J-hooks.
58. Raise the vehicle slowly off of the engine and transmission assembly. It may be necessary to move the engine/transmission assembly rearward in order to clear the intake manifold.
59. Separate the engine from the transmission.

Important: Place the bolts are in their correct locations.

1. Assemble the engine to the transmission.
2. Position the engine and the transmission assembly under the engine compartment.
3. Slowly lower the vehicle over the assembly until the transmission mount is indexed.
4. Install the bolt.
5. Install the J 28467-360 adjust to the previous setting.
6. Install the engine mount assembly. Refer to Engine Mount Replacement .



7. Install the transmission mount. Refer to Transmission Front Mount Replacement and Transmission Rear Mount Replacement in Manual Transmission-M86/M94 Getrag.
8. Raise the vehicle off of the support.
9. Install the axle shafts to the transmission. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
10. Connect the heater outlet hose to the radiator outlet pipe.



11. Install the suspension support upper bolts.



12. Install the suspension support lower bolts.



13. Install the suspension support center bolts and the support.
14. Install the ball joint nuts. Refer to Lower Control Arm Ball Joint Replacement in Front Suspension.
15. Install the engine strut mount. Refer to Engine Mount Strut Replacement .



16. Route the ABS wheel speed sensor harness.



17. Connect the VSS electrical connections.
18. Connect the knock sensor electrical connections.
19. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.



20. Connect the front ABS wheel speed sensors electrical connections.



21. Install the flywheel housing cover.
22. Connect the lower radiator hose. Refer to Radiator Hose Replacement in Engine Cooling.
23. Install the right engine splash shield. Refer to Engine Splash Shield Replacement in Body Front End.
24. Install the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
25. Lower the vehicle.
26. Remove the J 28467-360 .
27. Install the surge tank. Refer to Radiator Surge Tank Replacement in Engine Cooling.
28. Install the generator electrical connection.



29. Install the injector harness electrical connection.
30. Install the A/C compressor electrical connection, if equipped.



31. Install the IAC sensor electrical connection at the throttle body.



32. Install the TP sensor electrical connection at the throttle body.



33. Install the MAP sensor electrical connection .
34. Install the EVAP canister purge solenoid electrical connection.



35. Install the ground connections.



36. Install the negative battery cable to the transmission.



37. Install the engine coolant temperature sensor electrical connection.



38. Install the oil pressure sensor/switch electrical connection.



39. Install the O2S (Oxygen Sensor) electrical connection.
40. Install the crankshaft position sensor electrical connection.
41. Install the backup light switch electrical connection.



42. Install the electronic ignition coil and module assembly electrical connection.



43. Install the camshaft position sensor electrical connection.
44. Connect the vacuum hoses.
45. Connect the compressor/condenser hose assembly to the compressor, if A/C equipped. Refer to Compressor Hose Assembly Replacement in Heating, Ventilation and Air Conditioning.



46. Install the clutch actuator line.



47. Install the shift control housing.
48. Install the exhaust manifold and heat shield. Refer to Exhaust Manifold Replacement in Engine Exhaust.
49. Connect the fuel lines. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 2.4L.
50. Connect the positive battery cable to the battery.

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




51. Install the power steering pump to the block. Refer to Power Steering Pump Replacement in Power Steering System.
52. Install the power steering pump bolts.
53. Connect the vacuum hoses to 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.
54. Install the accelerator control cable bracket.



55. Install the throttle cable (1).
56. Install the coolant fan. Refer to Engine Cooling Fan Replacement in Engine Cooling.
57. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls-2.4L.
58. Install the radiator outlet (upper) hose. Refer to Radiator Hose Replacement in Engine Cooling.
59. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.



60. Connect the heater hose at the thermostat housing.
61. Check and fill the transmission with fluid. Refer to Transmission Fluid Check in Manual Transmission-M86 and M94 Getrag.
62. Fill engine oil.
63. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
64. If the vehicle is A/C equipped, evaporate, charge and leak test the A/C system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.