Removal and install engine assemblies

AURT201164A

AURT201164A Remove and install engine assemblies

Engine Assembly A: REMOVAL 1) Set the vehicle on a lift. 2) Open the front hood fully, and then support with the hood stay. 3) Collect the refrigerant from A/C system. 4) Release the fuel pressure. (a) Disconnect the fuel pump relay connector.

(b) Start the engine, and run until stalls. (c) After the engine stalls, crank it for 5 seconds more. (d) Turn the ignition switch to OFF. 5) Remove the filler cap. 6) Disconnect the ground cable from battery.

7) Remove the radiator from vehicle. 8) Remove the coolant filler tank. 9) Disconnect the A/C pressure hoses from A/C compressor.

Student Workbook AURT201164A Ver.1.0 XLTJAYPEE

AURT201164A Remove and install engine assemblies

10) Remove the intercooler. 11) Disconnect the following connectors and cable. (1) Engine harness connector

(2) Engine ground terminal

Student Workbook AURT201164A Ver.1.0 XLTJAYPEE

AURT201164A Remove and install engine assemblies

(3) Engine harness connector

(4) Generator connector, terminal and A/C compressor connectors

(5) Clutch release spring

Student Workbook AURT201164A Ver.1.0 XLTJAYPEE

AURT201164A Remove and install engine assemblies

12) Disconnect the following hoses. (1) Brake booster vacuum hose

(2) Heater inlet outlet hose 13) Remove the power steering pump from bracket. (1) Loosen the lock bolt and slider bolt, and then remove the front side V-belt. (2) Disconnect the power steering switch connector.

Student Workbook AURT201164A Ver.1.0 XLTJAYPEE

AURT201164A Remove and install engine assemblies

(3) Remove the pipe with bracket from intake manifold.

(4) Remove the power steering pump from engine.

(5) Remove the power steering tank from bracket by pulling it upward.

Student Workbook AURT201164A Ver.1.0 XLTJAYPEE

AURT201164A Remove and install engine assemblies

(6) Place the power steering pump on right side wheel apron.

15) Remove the center exhaust pipe. 16) Remove the nuts which hold the lower side of transmission to engine.

17) Remove the nuts which install the front cushion rubber onto front crossmember.

18) Lower the vehicle.

AURT201164A Remove and install engine assemblies

19) Separate the clutch release fork from release bearing. (1) Remove the clutch operating cylinder from transmission. (2) Remove the plug using a 10 mm hexagon wrench.

(3) Screw the 6 mm dia. bolt into release fork shaft, and remove it.

(A) Shaft (B) Bolt

AURT201164A Remove and install engine assemblies

(4) Raise the release fork, and then unfasten the release bearing tabs to free release fork. NOTE: Step (4) is required to prevent interference with engine when removing the engine from transmission. 20) Remove the pitching stopper.

21) Disconnect the fuel delivery hose, return hose and evaporation hose. NOTE: Catch fuel from the hose into container. Disconnect the hose with its end wrapped with cloth to prevent fuel from splashing.

Student Workbook AURT201164A Ver.1.0 XLTJAYPEE

AURT201164A Remove and install engine assemblies

22) Support the engine with a lifting device and wire ropes.

23) Support the transmission with a garage jack. NOTE: Before moving the engine away from transmission, check to be sure no work has been overlooked. Doing this is very important in order to facilitate re-installation and because transmission lowers under its own weight.

24) Separation of the engine and transmission. (1) Remove the starter. (2) Remove the bolts which hold the right upper side of transmission to engine.

Student Workbook AURT201164A Ver.1.0 XLTJAYPEE

AURT201164A Remove and install engine assemblies

25) Remove the engine from vehicle. (1) Slightly raise the engine. (2) Raise the transmission with garage jack. (3) Move the engine horizontally until the main shaft is withdrawn from clutch cover (4) Slowly move the engine away from engine compartment. NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil pressure gauge, etc. 26) Remove the front cushion rubbers. B: INSTALLATION 1) Install the clutch release fork and bearing onto transmission. (1) Remove the release bearing from clutch cover with flat type screw driver.

(2) Install the release bearing on transmission. (3) Install the release fork into release bearing tab.

(A) Release fork (B) Release bearing (4) Apply grease to the specified points. Spline Shaft
Student Workbook AURT201164A Ver.1.0 XLTJAYPEE

AURT201164A Remove and install engine assemblies

(5) Insert the release fork shaft into release fork.

(6) Tighten the plug.

2) Install the front cushion rubbers to engine. 3) Install the engine onto transmission. (1) Position the engine in engine compartment, and then align it with the transmission. NOTE: Be careful not to damage the adjacent parts or body panels with crank pulley, oil pressure gauge, etc. (2) Apply a small amount of grease to the splines of mainshaft.

4) Tighten the bolts which hold the right upper side of transmission to engine.
Student Workbook AURT201164A Ver.1.0 XLTJAYPEE

AURT201164A Remove and install engine assemblies

5) Remove the lifting device and wire ropes. 6) Remove the garage jack.

7) Install the pitching stopper.

8) Install the power steering pump on bracket. (1) Install the power steering tank on bracket.
Student Workbook AURT201164A Ver.1.0 XLTJAYPEE

AURT201164A Remove and install engine assemblies

(2) Install the power steering pump.

(3) Install the power steering pipe bracket on intake manifold RH.

(4) Connect the power steering switch connector

AURT201164A Remove and install engine assemblies

(5) Install the front side V-belt, and adjust it. 9) Lift-up the vehicle. 10) Tighten the nuts which hold the lower side of transmission to engine.

11) Tighten the nuts which install the front cushion rubber onto crossmember. NOTE: Make sure the front cushion rubber mounting bolts (A) and locator (B) are securely installed.

12) Install the center exhaust pipe. 13) Lower the vehicle.
Student Workbook AURT201164A Ver.1.0 XLTJAYPEE

AURT201164A Remove and install engine assemblies

14) Connect the following hoses: (1) Fuel delivery hose, return hose and evaporation hose (2) Heater inlet and outlet hoses (3) Brake booster vacuum hose 15) Connect the following connectors and terminals: (1) Engine ground terminal (2) Engine harness connectors (3) Generator connector and terminal (4) A/C compressor connectors 16) Install the air intake system. (1) Install the intercooler. (2) Install the air cleaner element and air cleaner upper cover. (3) Install the engine harness connector bracket. (4) Install the filler hose to air cleaner case. 17) Install the A/C pressure hoses. NOTE: Use new O-rings.

18) Install the radiator. 19) Install the coolant filler tank. 20) Install the window washer tank. 21) Install the battery in the vehicle, and then connect the cables. 22) Fill coolant. 23) Charge the A/C system with refrigerant. 24) Remove the front hood stay, and close the front hood. 25) Take off the vehicle from lift arms.

Student Workbook AURT201164A Ver.1.0 XLTJAYPEE

AURT201164A Remove and install engine assemblies

REMOVAL - ENGINE ASSEMBLY 1. Release fuel pressure. 2. Disconnect negative battery cable. 3. Drain cooling system. 4. Discharge A/C system using a suitable refrigerant recovery machine. 5. Remove throttle body air inlet hose and air cleaner housing assembly. 6. Raise vehicle on hoist. 7. Remove both front wheels. 8. Remove left and right splash shields. 9. Remove fasteners attaching lower front fascia to crossmember. 10. Remove fasteners attaching lower air shield to crossmember. 11. Remove front bumper fascia. 12. Lower vehicle. 13. Remove upper radiator crossmember. 14. Disconnect upper and lower radiator hoses at radiator. 15. Automatic Transmission Equipped Vehicles: Using a blade or suitable hose cutter, cut transaxle oil cooler lines off flush with fittings. Plug lines and fittings to prevent debris from entering transaxle or cooler circuit. A service splice kit will be installed upon reassembly Disconnect transmission electrical harness connectors. Disconnect transmission shift cable. 16. Manual Transmission Equipped Vehicles: Disconnect transmission shift cables and remove from retaining bracket. Disconnect back up lamp switch connector. 17. Disconnect A/C lines at condenser. Remove cooling module (fan, radiator, A/C condenser). 18. Disconnect engine electrical harness from PCM and bulkhead connectors. 19. Remove fasteners attaching ABS brake module to lower radiator crossmember. Support module with a suitable retaining strap. 20. Disconnect brake line from retaining clips that attach to lower radiator crossmember. 21. Raise vehicle. 22. Remove both axle shafts. 23. Remove front engine mount through bolt. Remove front engine mount from lower radiator crossmember. 24. Remove lower radiator crossmember. 25. Remove accessory drive belts. 26. Remove power steering pump and bracket as an assembly. Do not disconnect power steering lines from pump. Reposition pump and support with suitable retaining strap. 27. Disconnect heater return hose from pipe connection at right front frame rail area. 28. Disconnect A/C compressor electrical connector. 29. Remove A/C compressor mounting bolts. Reposition A/C compressor and support with suitable retaining strap. Generator can be removed with engine assembly. 30. Remove structural collar. 31. Remove the exhaust cross-under pipe. 32. Remove rear engine mount and transaxle bracket. 33. Drain engine oil. 34. Automatic Transmission Equipped Vehicles: Remove transaxle torque converter housing cover. Mark flex plate to torque converter position. Remove torque converter bolts. 35. Manual Transmission Equipped Vehicles: Using Special Tool 6638, disconnect clutch hydraulic circuit quick connect fitting. Remove clutch/drive plate inspection cover.
Student Workbook AURT201164A Ver.1.0 XLTJAYPEE

AURT201164A Remove and install engine assemblies

Mark flex plate to modular clutch position. Remove modular clutch assembly-to-drive plate bolts. 36. Lower vehicle. 37. Disconnect positive cable from battery and PDC. 38. Disconnect ground cable from left side transaxle mount bracket. 39. Disconnect throttle and speed control cables. 40. Disconnect coolant pressure bottle coolant hose from engine coolant outlet connector. 41. Disconnect heater hose from engine coolant outlet connector. 42. Disconnect ground strap at right shock tower. 43. Disconnect fuel line. 44. Disconnect brake booster and vapor purge vacuum hoses. 45. Disconnect all ground straps attaching to engine. 46. Position vehicle height to allow engine dolly 6135 and cradle 6710 with posts 47. Loosen cradle engine mounts to allow movement for positioning onto engine locating holes on the engine block, compressor mount bracket and oil pan rail. Lower vehicle and position cradle until the engine is resting on posts. Tighten post mounts to cradle frame to prevent movement when removing or installing engine/transaxle assembly. Secure engine/transaxle assembly to dolly/cradle with safety straps. 48. Lower vehicle so weight of the engine and transmission ONLY is on the cradle. 49. Remove right and left side engine mount bolts. 50. Slowly raise vehicle in short length spans. Inspect at each interval for potential engine or transaxle contact to vehicle components. Move the cradle/dolly fixture as necessary to allow for removal clearance.

INSTALLATION - ENGINE ASSEMBLY 1. Position engine/transaxle assembly under vehicle and slowly lower vehicle in short length spans. Inspect at each interval for potential engine or transaxle contact to vehicle components. Move the cradle/dolly fixture as necessary to allow for installation clearance. 2. Continue lowering vehicle until right side engine mount and left side transaxle mount align to their mounting locations. Install mounting bolts at specified torque. 3. Remove safety straps from engine/transaxle assembly. Slowly raise vehicle enough to remove the engine dolly and cradle. 4. Reattach all ground straps to engine. 5. Connect brake booster and vapor purge vacuum hoses. 6. Connect fuel line. 7. Connect ground strap to right shock tower. 8. Connect heater hose to coolant outlet connector. 9. Connect coolant pressure bottle coolant hose to coolant outlet connector. 10. Connect throttle and speed control cables. 11. Connect ground cable to left side transaxle mount bracket. 12. Connect positive cable to battery and PDC. 13. Raise vehicle. 14. Automatic Transmission Equipped Vehicles: Install torque converter bolts. Install torque converter housing cover. 15. Manual Transmission Equipped Vehicles: Install modular clutch assembly-to-drive plate bolts. Install clutch/drive plate inspection cover. Connect clutch hydraulic circuit quick connect fitting. 16. Install rear engine mount and transaxle bracket. 17. Install exhaust cross-under pipe. 18. Install structural collar. 19. Install A/C compressor to bracket.
Student Workbook AURT201164A Ver.1.0 XLTJAYPEE

AURT201164A Remove and install engine assemblies

20. Connect A/C compressor clutch electrical connector. 21. Connect heater return hose to pipe connection at right front frame rail area. 22. Install power steering pump and bracket assembly. 23. Install accessory drive belts. 24. Install lower radiator crossmember. 25. Install front engine mount to lower radiator crossmember. Install front engine mount through bolt. 26. Install both axle shafts. 27. Lower vehicle. 28. Connect brake line to retaining clips that attach to lower radiator crossmember. 29. Install fasteners attaching ABS module to lower radiator crossmember. 30. Connect engine electrical harness to PCM and bulkhead connectors. 31. Automatic Transmission Equipped Vehicles: Connect transmission shift cable. Connect transmission electrical harness connectors. Connect transmission oil cooler lines using service splice kit. Refer to instructions provided with kit. 32. Manual Transmission Equipped Vehicles: Connect transmission shift cables. Connect back up lamp switch connector. 33. Install cooling module (fan, radiator, A/C condenser). Connect A/C lines to condenser. 34. Connect upper and lower radiator hoses to radiator. 35. Install upper radiator crossmember. 36. Raise vehicle. 37. Ensure oil pan drain plug is tight. Install new oil filter. 38. Install front bumper fascia and lower air shield to lower radiator crossmember. 39. Install left and right splash shields. 40. Install both front wheels. 41. Lower vehicle. 42. Install throttle body air inlet hose and air cleaner housing assembly. 43. Fill engine crankcase with proper oil to correct level. 44. Evacuate and recharge Air Conditioning system. 45. Fill cooling system. 46. Connect negative battery cable. 47. Start engine and run until operating temperature is reached.

Student Workbook AURT201164A Ver.1.0 XLTJAYPEE