Special Tools

1. Discharge the air conditioning (A/C) system, if equipped.



2. Drain the power steering oil, if equipped.
3. Disconnect the negative battery cable.
4. Remove the engine cover. Refer to Engine Cover Replacement.
5. Remove the charge air system hoses and ducts. Refer to Charge Air Cooler Inlet Pipe and Outlet Pipe Replacement.
6. Drain the engine coolant. Refer to Cooling System Draining and Filling.



7. Disconnect the fuel feeding pipe connector (a).
8. Disconnect the coolant hose from the surge tank (b, c).
9. Disconnect the fuel return hose from the junction block (d).



10. Disconnect the engine wiring harness as follows:

•	Disconnect the fuel heater wiring connector (a).

•	Disconnect the mass air flow sensor (MAF) connector (b).

•	Disconnect the exhaust temperature sensor wiring connector (c).

•	Disconnect the DPF pressure sensor connector (d).

•	Disconnect the engine oil pressure switch connector (e).

•	Disconnect the common rail pressure sensor connector (f).

•	Disconnect the coolant temperature sensor connector (g).

•	Disconnect the EGR vacuum solenoid connector (h).

•	Disconnect the fuel injector connector (i).

•	Disconnect the camshaft position sensor (CMP) connector (j).

•	Disconnect the turbocharger actuator connector (k).

•	Disconnect the glow plug wire connector (l).

•	Disconnect the booster pressure (T-MAP) sensor connector (m)

•	Disconnect the common rail regulator connector (n).

•	Disconnect the ETC body connector (o).

•	Disconnect the fuel injection pump connector (p).

•	Disconnect the cooling fan connectors (q).

•	Disconnect the A/C compressor connector (r).

•	Disconnect the starter solenoid wiring connector (s).

•	Disconnect the A/C pressure sensor connector (t).

•	Disconnect the transaxle range (TR) switch connector, if auto-transaxle (u).

•	Disconnect the transaxle wiring electrical connector, if auto-transaxle (v).

•	Disconnect the input speed sensor electrical connector, if auto-transaxle (w).

•	Disconnect the output speed sensor electrical connector, if auto-transaxle (x).

•	Disconnect the speed sensor connector, if manual-transaxle (y).

•	Disconnect the crankshaft position sensor (z).

•	Disconnect the generator connector (B).




11. Remove the engine hardware and components as follows:

11.1.

Remove the engine splice pack tighten bolt from the intake manifold (1).

11.2.

Remove the glow plug module (2).

11.3.

Remove the glow plug fuse box (3).

11.4.

Remove the generator B+ connector nut (4).

11.5.

Remove the starter solenoid connector nut (5).

11.6.

Remove the engine ground bolt (6).




12. Remove the surge tank. Refer to Radiator Surge Tank Replacement.
13. Remove the power steering pump pipes from the power steering pump.
14. Remove the front drive axle shafts. Refer to Front Wheel Drive Shaft Replacement.
15. Remove the steering intermediate shaft lower pinch bolt.



16. For automatic transaxle, remove the shift control cable from the automatic transaxle. Refer to Shift Control Cable Replacement.



17. For manual transaxle, remove the select cable from the transaxle. Refer to Transmission Control Replacement.



18. For automatic transaxle, remove the transaxle oil cooler hoses from the auto-transaxle.



19. For manual transaxle, remove the clutch actuator cylinder pipe from the transaxle. Refer to Clutch Concentric Actuator Cylinder Replacement.



20. Remove the front exhaust pipe between the pre-catalyst and the diesel particulate filter pipe.



21. Remove the A/C compressor pipe from the compressor.
22. Remove the power steering return cooling pipe.
23. Remove the propeller shaft assembly from the transfer case, if equipped. Refer to Propeller Shaft Replacement.



24. Remove the cradle supporter bracket.




Note: Make sure all components are set on the exact position of the EN-48243 pallet with EN-48244 supporter .

25. Remove the cradle tightening bolts.

•	1-4 : Cradle Supporter

•	Diesel Engine Oil Pan Supporter

•	FAM II 2.4L Diesel Engine Oil Pan Supporter

•	HFV6 3.2L Engine Oil Pan Supporter

•	Manual Transaxle Supporter

•	Automatic Transaxle Supporter

•	Transfer Case Supporter (M/T & A/T)

•	Transaxle Mount Supporter (M/T & A/T)





Note: Only lower the vehicle far enough to take the weight off the engine and transaxle mount, or damage to the mount and pallet/pallet supporter failure may occur.

26. Lower the vehicle and position the engine assembly on to the EN-48243 pallet with the EN-48244 supporter to the cradle.



27. Remove the engine mount bolt from the engine mount bracket.



28. Remove the transaxle mount bolt from the transaxle.



29. Tighten the engine assembly using by hoist, etc.
30. Remove the transaxle front mount.



31. Remove the transaxle rear mount.



32. Remove the engine and transaxle.

Caution: Refer to Fastener Caution in the Preface section.




1. Install the transaxle to engine assembly and tighten.

•	The transaxle tightening bolts to 75 N·m (55.3 lb ft).

•	The oil pan flange-to-transaxle bolts to 50 N·m (36.9 lb ft).

Note: Make sure all the components are set on the exact position on the EN-48243 Engine Assembly Remove/Install Pallet with EN-48244.

2. Install the cradle on the EN-48243 pallet with the EN-48244 supporter and then assemble the engine and the transaxle onto the cradle.



3. Lower the vehicle and position the engine and transaxle assembly with the cradle attached on to the EN-48243 with the EN-48244 supporter to the vehicle.



4. Install the transaxle rear mount and tighten the bolt to 90 N·m (66.4 lb ft).



5. Install the transaxle front mount and tighten the bolt to 90 N·m (66.4 lb ft).



6. Install the transaxle mount and tighten.

•	The transaxle mount assembly retaining bolts (2) to 37 N·m (27 lb ft).

•	The transaxle mount bracket retaining bolts (1) to 50 N·m (37 lb ft).




7. Install the engine mount bolt and tighten the retaining bolts to 50 N·m (37 lb ft).



8. Remove the EN-48243 pallet with the EN-48244 supporter from the vehicle.
9. Install the cradle to body mounting bolts and tighten to 155  N·m (114.3 lb ft).
10. Install the cradle support bracket retaining bolts and tighten to 50 N·m (36.9 lb ft).



11. Connect the engine wiring harness.

•	Connect the fuel heater wiring connector (a).

•	Connect the mass air flow sensor (MAF) connector (b).

•	Connect the exhaust temperature sensor wiring connector (c).

•	Connect the DPF pressure sensor connector (d).

•	Connect the engine oil pressure switch connector (e).

•	Connect the common rail pressure sensor connector (f).

•	Connect the coolant temperature sensor connector (g).

•	Connect the EGR vacuum solenoid connector (h).

•	Connect the fuel injector connector (i).

•	Connect the camshaft position sensor (CMP) connector (j).

•	Connect the turbocharger actuator connector (k).

•	Connect the glow plug wire connector (l).

•	Connect the booster pressure (T-MAP) sensor connector (m)

•	Connect the common rail regulator connector (n).

•	Connect the ETC body connector (o).

•	Connect the fuel injection pump connector (p).

•	Connect the cooling fan connectors (q).

•	Connect the A/C compressor connector (r).

•	Connect the starter solenoid wiring connector (s).

•	Connect the A/C pressure sensor connector (t).

•	Connect the transaxle range (TR) switch connector, if auto-transaxle (u).

•	Connect the transaxle wiring electrical connector, if auto-transaxle (v).

•	Connect the input speed sensor electrical connector, if auto-transaxle (w).

•	Connect the output speed sensor electrical connector, if auto-transaxle (x).

•	Connect the speed sensor connector, if manual-transaxle (y).

•	Connect the crankshaft position sensor (z).

•	Connect the generator connector (B).

12. Install the engine hardware and components as follows:

12.1.

Install the engine splice pack tighten bolt from the intake manifold (1) and tighten the bolt to 15 N·m (11.1 lb ft).

12.2.

Install the glow plug module (2) and tighten the retaining nut to 14  N·m (10.3 lb ft).

12.3.

Install the glow plug fuse box (3) and tighten the bolts to 10 N·m (88.5 lb in).

12.4.

Install the generator B+ connector nut (4) and tighten to 25 N·m (18.4 lb ft).

12.5.

Install the starter solenoid connector nut (5) and tighten to 15 N·m (11.1 lb ft).

12.6.

Install the engine ground bolt (6) and tighten to 25 N·m (18.4 lb ft).