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.