Aura, Outlook 2007

Engine

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Removal & Installation



2.4L Engine
  1. Relieve the fuel system pressure.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Disconnect the fuel feed pipe quick connect fitting at the fuel rail.
  6.  
  7. Disconnect the Evaporative Emission (EVAP) line) quick connect fitting from the EVAP purge solenoid.
  8.  
  9. Remove the fuel feed pipe clip from the fuel line bracket.
  10.  
  11. Remove the transaxle shift cable clip from the fuel line bracket.
  12.  
  13. Remove the battery tray.
  14.  
  15. Remove the alternator starter.
  16.  
  17. Reposition the vacuum brake booster hose clamp) at the intake manifold.
  18.  
  19. Remove the vacuum brake booster hose from the intake manifold. Reposition the brake booster hose out of the way.
  20.  
  21. Remove the coolant recovery inlet hose clamp at the cylinder head.
  22.  
  23. Remove the coolant recovery inlet pipe clip from the fuel rail.
  24.  
  25. Remove the coolant recovery inlet hose from the cylinder head. Reposition the hose/pipe out of the way.
  26.  
  27. Reposition the radiator inlet hose clamp.
  28.  
  29. Remove the radiator inlet hose from the cylinder head.
  30.  
  31. Remove the radiator outlet hose.
  32.  
  33. Reposition the alternator control module coolant hose clamp at the alternator control module.
  34.  
  35. Remove the alternator control module coolant hose from the alternator control module.
  36.  
  37. Disconnect the engine wiring harness electrical connector from the transaxle auxiliary pump module.
  38.  
  39. Reposition the heater inlet hose clamp at the thermostat housing.
  40.  
  41. Remove the heater inlet hose from the thermostat housing.
  42.  
  43. Reposition the coolant recovery reservoir/heater inlet hose clamp at the thermostat housing.
  44.  
  45. Remove the coolant recovery reservoir/heater inlet hose from the thermostat housing.
  46.  
  47. Raise and support the vehicle.
  48.  
  49. Drain the engine oil.
  50.  
  51. Disconnect the engine wiring harness electrical connector) from the alternator control module coolant pump.
  52.  
  53. Disconnect the engine wiring harness electrical connector from the Air Conditioning (A/C) compressor.
  54.  
  55. Remove the alternator control module coolant pump bolt and pump.
  56.  
  57. Unbolt the A/C compressor and reposition out of the way.
  58.  
  59. Remove the positive battery cable to starter motor nut.
  60.  
  61. Remove the positive battery cable lead from the starter motor.
  62.  
  63. Remove the positive battery cable from in between the starter and the engine. Reposition the positive battery cable out of the way.
  64.  
  65. Disconnect the engine wiring harness electrical connector from the auxiliary heater water pump.
  66.  
  67. Remove the auxiliary heater water pump bolt and pump.
  68.  
  69. Lower the vehicle.
  70.  
  71. Remove the transaxle shift cable from the range select lever.
  72.  
  73. Release the shift control cable retaining clip and remove the cable from the shift control cable bracket.
    NOTE
    The radiator/condenser/fan assembly will stay in the vehicle during engine removal.

  74.  
  75. Using long tie straps, secure the radiator/condenser/fan assembly to the radiator support.
  76.  
  77. Raise the vehicle.
  78.  
  79. Remove the front wheels and tires.
  80.  
  81. Remove the front fender liners.
    NOTE
    A piece of hardwood should be used between the transaxle and the engine cradle. This wood will support the engine when the left side engine mounts bolts are removed.

  82.  
  83. Install a piece of hardwood 1 x 2 x 4 between the transaxle and the engine cradle.
  84.  
  85. Drain the transaxle fluid.
  86.  
  87. Remove the transaxle oil cooler line to transaxle nut.
  88.  
  89. Remove the transaxle oil cooler lines from the transaxle.
  90.  
  91. Remove the catalytic converter.
    NOTE
    Secure the steering wheel in the straight forward position before separating the intermediate shaft from the steering gear, or damage to the SIR coil will occur.

  92.  
  93. Remove the intermediate to steering gear pinch bolt and disconnect the intermediate shaft from the steering gear. Discard the pinch bolt.
  94.  
  95. Remove and discard both outer tie rod to steering knuckle nuts.
    NOTE
    Hold the ball stud to prevent turning during removal of the nut.

  96.  
  97. Separate the tie rods from the steering knuckles.
  98.  
  99. Remove the stabilizer link to stabilizer shaft nuts and disconnect the stabilizer links from the stabilizer shaft.
  100.  
  101. Remove and discard both of the lower control arm ball stud cotter pins.
  102.  
  103. Loosen the ball stud nuts until the nuts are level with the top of the ball stud.
  104.  
  105. Separate the lower control arms from the steering knuckles.
  106.  
  107. Remove the ball stud nuts.
  108.  
  109. Remove the wheel drive shafts.
  110.  
  111. Lower the vehicle.
  112.  
  113. Remove the engine mount to bracket bolts.
  114.  
  115. Remove the transaxle mount to transaxle bolts.
  116.  
  117. Raise the vehicle.
    NOTE
    During the powertrain removal support the vehicle body by placing a jack at the rear of the vehicle. Position a engine support table under the powertrain assembly.


    NOTE
    Blocks of wood can be used between the front of the cradle and the oil pan to table in order to level the powertrain during the removal.

  118.  
  119. With the table positioned, fully raise the table to contact with the powertrain assembly.
  120.  
  121. Remove the cradle to body bolts. Discard the bolts.
    NOTE
    When lowering the engine/transaxle assembly, verify all brake lines, shifter cables and other components are free during removal.

  122.  
  123. Lower the engine table and raise the body on the hoist until the engine/transaxle and cradle are free from the vehicle.
  124.  
  125. Disconnect the engine wiring harness electrical connector from the throttle actuator.
  126.  
  127. Disconnect the engine wiring harness electrical connector from the fuel injector wiring harness electrical connector.
  128.  
  129. Remove the engine wiring harness clip from the oil level indicator tube bracket.
  130.  
  131. Disconnect the engine wiring harness electrical connectors from the ignition coils.
  132.  
  133. Disconnect the engine wiring harness electrical connectors from the camshaft actuators.
  134.  
  135. Disconnect the engine wiring harness electrical connector from the Crankshaft Position (CKP) sensor.
  136.  
  137. Disconnect the engine wiring harness electrical connector from the oil pressure sensor.
  138.  
  139. Disconnect the engine wiring harness electrical connector from the knock sensor.
  140.  
  141. Disconnect the engine wiring harness electrical connector from the intake Camshaft Position (CMP) sensor.
  142.  
  143. Disconnect the engine wiring harness electrical connector from the EVAP emission canister purge solenoid valve.
  144.  
  145. Disconnect the engine wiring harness electrical connector from the exhaust CMP sensor.
  146.  
  147. Disconnect the engine wiring harness electrical connector) from the Engine Coolant Temperature (ECT) sensor.
  148.  
  149. Disconnect the engine wiring harness electrical connector from the Heated Oxygen Sensor (HO2S) electrical connector.
  150.  
  151. Remove the engine wiring harness clip from the stud.
  152.  
  153. Remove the engine wiring harness ground bolt and reposition the ground terminal from the engine.
  154.  
  155. Gather all branches of the engine wiring harness and reposition the harness out of the way.
  156.  
  157. Remove the starter motor bolts and starter.
  158.  
  159. Remove the torque converter to flexplate bolts.
  160.  
  161. Install a suitable lifting devise to the engine.
  162.  
  163. Remove the transaxle bolts from the engine.
  164.  
  165. Separate the engine from the transaxle.
  166.  
  167. Install the engine to a suitable engine stand.
  168.  

To install:

  1. Install a suitable lifting devise to the engine.
  2.  
  3. Using the lifting devise, position and install the engine to the transaxle.
  4.  
  5. Install the transaxle bolts to the engine and tighten to 55 ft. lbs. (75 Nm).
  6.  
  7. Install the torque converter to flexplate bolts and tighten to 44 ft. lbs. ( 60 Nm).
  8.  
  9. Remove the engine lifting devise.
  10.  
  11. Install the starter motor and bolts. Tighten to 39 ft. lbs. (53 Nm).
  12.  
  13. Gather all branches of the engine wiring harness and position the harness to the engine.
  14.  
  15. Position the engine wiring harness ground terminal to the engine and install the engine wiring harness ground bolt and tighten the bolts to 15 ft. lbs. (20 Nm).
  16.  
  17. Connect the engine wiring harness electrical connector to the ECT sensor.
  18.  
  19. Connect the engine wiring harness electrical connector to the HO2S electrical connector.
  20.  
  21. Install the engine wiring harness clip to the stud.
  22.  
  23. Connect the engine wiring harness electrical connector to the exhaust CMP sensor.
  24.  
  25. Connect the engine wiring harness electrical connector to the intake CMP sensor.
  26.  
  27. Connect the engine wiring harness electrical connector to the EVAP emission canister purge solenoid valve.
  28.  
  29. Connect the engine wiring harness electrical connector to the CKP sensor.
  30.  
  31. Connect the engine wiring harness electrical connector to the oil pressure sensor.
  32.  
  33. Connect the engine wiring harness electrical connector to the knock sensor.
  34.  
  35. Connect the engine wiring harness electrical connectors to the ignition coils.
  36.  
  37. Connect the engine wiring harness electrical connectors to the camshaft actuators.
  38.  
  39. Connect the engine wiring harness electrical connector to the throttle actuator.
  40.  
  41. Connect the engine wiring harness electrical connector to the fuel injector wiring harness electrical connector .
  42.  
  43. Install the engine wiring harness clip to the oil level indicator tube bracket.
  44.  
  45. Position the powertrain and support table under the vehicle.
  46.  
  47. Raise the powertrain into position under the vehicle.
  48.  
  49. With the table positioned, if required, lower the vehicle over the powertrain.
  50.  
  51. Align the lower radiator pins with the cradle. Ensure all hoses and electrical harnesses are correctly routed and free from the loading path of the powertrain.
  52.  
  53. Install the NEW cradle to body bolts and tighten to 114 ft. lbs. (155 Nm).
  54.  
  55. Lower the vehicle.
  56.  
  57. Install the transaxle mount to transaxle bolts. Tighten to 41 ft. lbs. (55 Nm).
    NOTE
    The engine mount to bracket bolts must be hand started. Do not pry the engine mount to align the holes.

  58.  
  59. Install the engine mount to bracket bolts and tighten to 37 ft. lbs. (50 Nm).
  60.  
  61. Install the wheel drive shafts.
  62.  
  63. Install the control arm ball studs into the steering knuckles.
  64.  
  65. Install the ball stud nuts and tighten to 30 ft. lbs. (40 Nm).
  66.  
  67. Continue to tighten the nuts only enough to align the castle nut slots with the ball stud, install NEW cotter pins.
  68.  
  69. Connect the stabilizer links to the stabilizer shaft and install the stabilizer link to stabilizer shaft nuts. Tighten to 48 ft. lbs. (65 Nm).
  70.  
  71. Connect the outer tie rods to the steering knuckles. Tighten to 30 ft. lbs. (40 Nm).
  72.  
  73. Install NEW outer tie rod to steering knuckle nuts. Tighten to 48 ft. lbs. (65 Nm) plus an additional 90 degrees.
  74.  
  75. Position the intermediate shaft to the steering gear and install a NEW pinch bolt. Tighten to 25 ft. lbs. (34 Nm).
  76.  
  77. Install the catalytic converter.
  78.  
  79. Install the transaxle oil cooler lines to the transaxle.
  80.  
  81. Install the transaxle oil cooler line to transaxle nut. Tighten to 27 in. lbs. (4 Nm).
  82.  
  83. Remove the wood from between the oil pan and the engine cradle.
  84.  
  85. Remove the wood from between the transaxle and the engine cradle.
  86.  
  87. Install the front fender liners.
  88.  
  89. Install the front wheels and tires.
  90.  
  91. Lower the vehicle.
  92.  
  93. Unsecure and position the radiator/condenser/fan assembly.
  94.  
  95. Install the shift control cable to the shift control cable bracket and engage the shift control cable retaining clip.
  96.  
  97. Install the transaxle shift cable to the range select lever.
  98.  
  99. Raise and support the vehicle.
  100.  
  101. Install the auxiliary heater water pump and bolt. Tighten the bolt to 80 in. lbs. (9 Nm).
  102.  
  103. Connect the engine wiring harness electrical connector to the auxiliary heater water pump.
  104.  
  105. Position and install the positive battery cable between the starter and the engine.
  106.  
  107. Install the positive battery cable lead to the starter motor.
  108.  
  109. Install the positive battery cable to starter motor nut.
  110.  
  111. Position the A/C compressor and install the bolts. Tighten to 37 ft. lbs. (50 Nm).
  112.  
  113. Install the alternator control module coolant pump and bolt. Tighten to 18 ft. lbs. (25 Nm).
  114.  
  115. Connect the engine wiring harness electrical connector to the alternator control module coolant pump.
  116.  
  117. Connect the engine wiring harness electrical connector to the A/C compressor.
  118.  
  119. Lower the vehicle.
  120.  
  121. Install the coolant recovery reservoir/heater inlet hose to the thermostat housing.
  122.  
  123. Position the coolant recovery reservoir/heater inlet hose clamp at the thermostat housing.
  124.  
  125. Install the heater inlet hose to the thermostat housing.
  126.  
  127. Position the heater inlet hose clamp at the thermostat housing.
  128.  
  129. Connect the engine wiring harness electrical connector to the transaxle auxiliary pump module.
  130.  
  131. Install the alternator control module coolant hose to the alternator control module.
  132.  
  133. Position the alternator control module coolant hose clamp at the alternator control module.
  134.  
  135. Reposition the radiator inlet hose clamp.
  136.  
  137. Remove the radiator inlet hose from the cylinder head.
  138.  
  139. Remove the radiator outlet hose.
  140.  
  141. Position and install the coolant recovery inlet hose to the cylinder head.
  142.  
  143. Install the coolant recovery inlet pipe clip to the fuel rail.
  144.  
  145. Install the coolant recovery inlet hose clamp at the cylinder head.
  146.  
  147. Position and install the vacuum brake booster hose to the intake manifold.
  148.  
  149. Position the vacuum brake booster hose clamp at the intake manifold.
  150.  
  151. Install the alternator starter.
  152.  
  153. Install the battery tray.
  154.  
  155. Install the transaxle shift cable clip to the fuel line bracket.
  156.  
  157. Install the fuel feed pipe clip (2) to the fuel line bracket.
  158.  
  159. Connect the EVAP line quick connect fitting to the EVAP purge solenoid.
  160.  
  161. Connect the fuel feed pipe quick connect fitting at the fuel rail.
  162.  
  163. Install the air cleaner assembly.
  164.  
  165. Fill the transaxle with fluid.
  166.  
  167. Refill the engine with oil.
  168.  
  169. Start the engine and allow the engine to run, inspect for leaks. Correct as necessary.
  170.  

3.5L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the intake manifold cover.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Remove the air cleaner assembly.
  10.  
  11. Remove the hood.
  12.  
  13. Remove the engine mount strut.
  14.  
  15. Remove the drive belt.
  16.  
  17. Disconnect the front Knock Sensor (KS).
  18.  
  19. Disconnect the rear Knock Sensor (KS).
  20.  
  21. Disconnect the Camshaft Position (CMP) sensor, Crankshaft Position (CKP) sensor and the oil control valves.
  22.  
  23. Disconnect the Manifold Absolute Pressure (MAP) sensor.
  24.  
  25. Disconnect the Evaporative Emission (EVAP) canister purge solenoid.
  26.  
  27. Disconnect the front and rear ignition coils.
  28.  
  29. Disconnect the A/C compressor.
  30.  
  31. Disconnect the coolant temperature sensor.
  32.  
  33. Disconnect the following electrical connectors:
    1. The Heated Oxygen Sensor (HO2S)
    2.  
    3. The Exhaust Gas Recirculation (EGR) valve
    4.  
    5. The electronic throttle control
    6.  
    7. The body wiring harness-to-engine harness
    8.  

  34.  
  35. Raise and support the vehicle.
  36.  
  37. Remove the catalytic converters. Remove the engine wiring harness grounds from the transaxle.
  38.  
  39. Remove the engine mount lower bolts.
  40.  
  41. Remove the torque converter covers.
  42.  
  43. Remove the starter motor.
  44.  
  45. Remove the Air Conditioning (A/C) compressor. DO NOT discharge the A/C system. Support the compressor.
  46.  
  47. Remove the torque converter bolts.
  48.  
  49. Remove the engine mount bracket.
  50.  
  51. Remove the transaxle to oil pan brace bolts and brace.
  52.  
  53. Remove the lower transaxle-to-engine bolt and the stud.
  54.  
  55. Remove the radiator outlet hose from the engine.
  56.  
  57. Lower the vehicle and support the transaxle.
  58.  
  59. Remove the heater outlet and inlet hoses from the engine.
  60.  
  61. Remove the vacuum hoses from the upper intake manifold.
  62.  
  63. Remove the brake booster vacuum hose from the upper intake manifold.
  64.  
  65. Remove the fuel lines from the fuel rail.
  66.  
  67. Remove the radiator inlet hose from the engine.
  68.  
  69. Install the engine lifting device to the engine.
  70.  
  71. Remove the upper transaxle-to-engine bolts and the stud.
  72.  
  73. Remove the engine from the vehicle.
  74.  
  75. Remove the flywheel.
  76.  
  77. Install the engine to the engine stand.
  78.  

To install:

  1. Remove the engine from the engine stand.
  2.  
  3. Install the flywheel.
  4.  
  5. Install the engine to the vehicle.
  6.  
  7. Install the upper transaxle-to-engine bolts and the stud. Tighten the bolts and the stud to 55 ft. lbs. (75 Nm).
  8.  
  9. Remove the engine lifting device.
  10.  
  11. Install the radiator inlet hose to the engine.
  12.  
  13. Install the fuel lines to the fuel rail.
  14.  
  15. Install the brake booster vacuum hose to the upper intake manifold.
  16.  
  17. Install the vacuum hoses to the upper intake manifold.
  18.  
  19. Install the heater inlet and outlet hoses to the engine.
  20.  
  21. Raise the vehicle and remove the transaxle support.
  22.  
  23. Install the radiator outlet hose to the engine.
  24.  
  25. Install the lower transaxle-to-engine bolt and the stud. Tighten the bolts and the stud to 55 ft. lbs. (75 Nm).
  26.  
  27. Position the transaxle to oil pan brace and install the bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).
  28.  
  29. Install the engine mount bracket.
  30.  
  31. Install the torque converter bolts.
  32.  
  33. Install the A/C compressor.
  34.  
  35. Install the starter motor.
  36.  
  37. Install the torque converter covers.
  38.  
  39. Install the engine mount lower bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).
  40.  
  41. Install the engine wiring harness grounds to the transaxle.
  42.  
  43. Install the engine wiring harness ground nut to the transaxle stud. Tighten the nut to 26 ft. lbs. (35 Nm).
  44.  
  45. Install the catalytic converters.
  46.  
  47. Lower the vehicle.
  48.  
  49. Install the remaining components in the reverse order of removal.
  50.  
  51. Fill the crankcase with engine oil.
  52.  
  53. Fill cooling system.
  54.  
  55. Inspect for leaks. Top of Form Bottom of Form
  56.  

3.6L Engine
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the intake manifold cover.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Remove the air cleaner assembly.
  10.  
  11. Remove the hood.
  12.  
  13. Remove the engine mount strut.
  14.  
  15. Remove the drive belt.
  16.  
  17. Disconnect the front Knock Sensor (KS).
  18.  
  19. Disconnect the rear KS and the crank sensor.
  20.  
  21. Re-position the plastic wire loom/shield on each valve cover, then disconnect the Camshaft Position (CMP) sensor.
  22.  
  23. Disconnect the Manifold Absolute Pressure (MAP) sensor.
  24.  
  25. Disconnect the Evaporative Emission (EVAP) canister purge solenoid.
  26.  
  27. Disconnect the front and rear ignition coils.
  28.  
  29. Disconnect the A/C compressor.
  30.  
  31. Disconnect the coolant temperature sensor, Heated Oxygen Sensor (HO2S), Exhaust Gas Recirculation (EGR) valve, electronic throttle control and body wiring harness-to-engine harness. Raise and support the vehicle. Remove the catalytic converters.
  32.  
  33. Remove the engine wiring harness grounds from the transaxle.
  34.  
  35. Remove the engine mount lower bolts.
  36.  
  37. Remove the torque converter covers.
  38.  
  39. Remove the starter motor.
  40.  
  41. Remove the Air Conditioning (A/C) compressor. DO NOT discharge the A/C system. Support the compressor.
  42.  
  43. Remove the power steering pump and position aside.
  44.  
  45. Remove the torque converter bolts.
  46.  
  47. Remove the engine mount bracket.
  48.  
  49. Remove the transaxle to oil pan brace bolts and brace.
  50.  
  51. Remove the lower transaxle-to-engine bolt and the stud.
  52.  
  53. Remove the radiator outlet hose from the engine.
  54.  
  55. Lower the vehicle and support the transaxle.
  56.  
  57. Remove the engine coolant thermostat housing from the engine.
  58.  
  59. Remove the vacuum hoses from the upper intake manifold.
  60.  
  61. Remove the brake booster vacuum hose from the upper intake manifold.
  62.  
  63. Remove the fuel lines from the fuel rail.
  64.  
  65. Remove the battery ground from the rear of engine.
  66.  
  67. Remove the radiator inlet hose from the engine.
  68.  
  69. Install the engine lifting device to the engine.
  70.  
  71. Remove the upper transaxle-to-engine bolts and the stud.
  72.  
  73. Remove the engine from the vehicle.
  74.  
  75. Remove the flywheel.
  76.  
  77. Install the engine to the engine stand.
  78.  

To install:

  1. Remove the engine from the engine stand.
  2.  
  3. Install the flywheel. Install the engine to the vehicle.
  4.  
  5. Install the upper transaxle-to-engine bolts and the stud. Tighten to 55 ft. lbs. (75 Nm).
  6.  
  7. Remove the engine lifting device.
  8.  
  9. Install the radiator inlet hose to the engine.
  10.  
  11. Install the battery ground to the rear of engine. Install the fuel lines to the fuel rail.
  12.  
  13. Install the brake booster vacuum hose to the upper intake manifold.
  14.  
  15. Install the vacuum hoses to the upper intake manifold.
  16.  
  17. Install the engine coolant thermostat housing to the engine.
  18.  
  19. Raise the vehicle and remove the transaxle support.
  20.  
  21. Install the radiator outlet hose to the engine.
  22.  
  23. Install the lower transaxle-to-engine bolt and the stud. Tighten to 55 ft. lbs. (75 Nm).
  24.  
  25. Position the transaxle to oil pan brace and install the bolts. Tighten to 37 ft. lbs. (50 Nm).
  26.  
  27. Install the engine mount bracket.
  28.  
  29. Install the torque converter bolts.
  30.  
  31. Install the power steering pump.
  32.  
  33. Install the A/C compressor.
  34.  
  35. Install the starter motor.
  36.  
  37. Install the torque converter covers.
  38.  
  39. Install the engine mount lower bolts. Tighten to 37 ft. lbs. (50 Nm).
  40.  
  41. Install the engine wiring harness grounds to the transaxle.
  42.  
  43. Install the engine wiring harness ground nut to the transaxle stud. Tighten to 26 ft. lbs. (35 Nm).
  44.  
  45. Install the remaining components in the reverse order of removal.
  46.  
  47. Fill the crankcase with engine oil.
  48.  
  49. Fill cooling system.
  50.  
  51. Inspect for leaks.
  52.  

  1. Remove the fuel injector sight shield.
  2.  
  3. Release the clamp from the brake booster vacuum hose connection.
  4.  
  5. Disconnect the brake booster vacuum hose from the intake manifold.
  6.  
  7. Remove the air cleaner assembly.
  8.  
  9. Properly relieve the fuel system pressure.
  10.  
  11. Disconnect the Evaporative Emission (EVAP) hose/pipe from the EVAP canister purge solenoid valve.
  12.  
  13. Disconnect the engine fuel hose/pipe from the chassis fuel hose/pipe.
  14.  
  15. Discharge the Air Conditioning (A/C) system.
  16.  
  17. Remove the A/C compressor suction hose assembly from the compressor. Cap or plug the hoses and compressor to prevent contamination.
  18.  
  19. Remove the A/C compressor discharge hose assembly from the compressor. Cap or plug the hoses and compressor to prevent contamination.
  20.  
  21. Drain and recycle the engine coolant.
  22.  
  23. Remove the coolant recovery reservoir.
  24.  
  25. Disconnect the inlet coolant heater hose from the engine.
  26.  
  27. Disconnect the outlet coolant heater hose from the engine.
  28.  
  29. Remove the radiator inlet hose.
  30.  
  31. Raise and support the vehicle.
  32.  
  33. Remove the radiator outlet hose.
  34.  
  35. Remove the exhaust flexible pipe and secure the rear half of the exhaust system to the vehicle underbody.
  36.  
  37. Remove the front tires.
  38.  
  39. Remove the steering intermediate shaft pinch bolt and discard the bolt.
  40.  
  41. Disconnect the steering intermediate shaft from the steering gear.
  42.  
  43. Disconnect the transaxle shift cable.
  44.  
  45. Disconnect the transaxle cooler lines.
  46.  
  47. Disconnect the negative battery extension cable.
  48.  
  49. Disconnect all engine electrical connectors.
  50.  
  51. Remove the right and left steering linkage outer tie rod ends from the steering knuckles.
  52.  
  53. Remove the right and left stabilizer shaft links from the stabilizer shaft.
  54.  
  55. Remove the right and left lower ball joints from the steering knuckles.
  56.  
  57. Place a drain pan under the transaxle then separate the right and left front wheel drive shafts from the transaxle/transfer case.
  58.  
  59. On All Wheel Drive (AWD) models, remove the propeller shaft.
  60.  
  61. Lower the vehicle.
  62.  
  63. Remove the engine mount strut.
    NOTE
    Insure the vehicle body is secured to the hoist.

  64.  
  65. Raise the vehicle.
  66.  
  67. Place a universal frame support fixture or jackstands under the frame.
  68.  
  69. Lower the vehicle until the frame contacts the frame support fixture or jackstands.
  70.  
  71. Remove the subframe to body bracket bolts.
  72.  
  73. Remove the frame-to-body bolts. Discard the bolts.
    NOTE
    Inspect for areas of body to powertrain contact or entanglement of wires and hoses while separating the vehicle body and powertrain.

  74.  
  75. Carefully raise the vehicle body up away from the powertrain.
  76.  
  77. Disconnect the engine electrical wiring harness from the following:

    Oxygen sensor
     
    EVAP purge solenoid
     
    Ignition coils 
     
    Ground lead
     

  78.  
  79. Remove the wire harness from retainers.
  80.  
  81. Disconnect the left and right cylinder head engine electrical wiring harness from the Camshaft Position (CMP) sensors and actuators.
  82.  
  83. Disconnect the engine electrical wiring harness from the following:

    Alternator
     
    Retainer clips
     
    A/C compressor hose
     
    Oil pressure switch 
     
    A/C compressor
     
    Battery cable
     
    Retainer clips 
     
    Transmission module
     

  84.  
  85. If equipped with an engine coolant heater, disconnect the coolant heater cord.
  86.  
  87. Remove the throttle body assembly.
  88.  
  89. Remove the engine-to-transaxle brace bolts and brace.
  90.  
  91. Remove the starter motor.
  92.  
  93. Remove the torque converter bolts.
  94.  
  95. Install an engine lift chain to the engine lift brackets.
  96.  
  97. Support the engine weight with an engine hoist.
  98.  
  99. Remove the automatic transaxle bolts.
  100.  
  101. Separate the automatic transaxle from the engine.
  102.  
  103. Lift the engine away from the frame and the automatic transaxle.
  104.  
  105. Secure the engine to an engine stand.
  106.  
  107. Remove any additional engine components as necessary. Refer to appropriate component sections in manual if needed.
  108.  
  109. Remove the engine from the engine stand.
  110.  
  111. Align the engine to the frame and automatic transaxle.
  112.  
  113. Install the transaxle-to-engine bolts. Tighten to 55 ft. lbs. (75 Nm).
  114.  
  115. Place a block of wood between the frame and the engine oil pan in order to support the engine on the frame once the engine hoist is removed.
  116.  
  117. Remove the engine hoist and lift chain.
  118.  
  119. Install the torque converter bolts. Tighten to 44 ft. lbs. (60 Nm).
  120.  
  121. Install the starter motor.
  122.  
  123. Install the engine to transaxle brace and bolts . Tighten the bolts to 37 ft. lbs. (50 Nm).
  124.  
  125. Install the throttle body assembly.
  126.  
  127. If equipped with an engine coolant heater, connect the coolant heater cord.
  128.  
  129. Connect the engine electrical wiring harness to the following:

    Transmission module
     
    Retainer clips 
     
    Battery cable. Tighten to 18 ft. lbs. (25 Nm)
     
    A/C compressor
     
    Oil pressure switch 
     
    A/C compressor hose
     
    Retainer clips
     
    Alternator
     

  130.  
  131. Connect the left and right cylinder head engine electrical wiring harness to the CMP sensors and actuators.
  132.  
  133. Connect the engine electrical wiring harness to the following:
  134.  
  135. Retainers.

    Ground lead
     
    Ignition coils 
     
    EVAP purge solenoid
     
    Oxygen sensor Install NEW frame-to-body bolts. Tighten to 114 ft. lbs. (155 Nm).
     

  136.  
  137. Install the subframe to body bracket bolts.
  138.  
  139. Raise the vehicle up away from the frame support fixture or jackstands and remove the support fixture or jackstands from under the vehicle.
  140.  
  141. Lower the vehicle.
  142.  
  143. Install the left transaxle mount bracket.
  144.  
  145. Install the engine mount strut.
  146.  
  147. Raise the vehicle.
  148.  
  149. On AWD models, install the propeller shaft.
  150.  
  151. On FWD models, install the right and left front wheel drive shafts into the transaxle.
  152.  
  153. Install the right and left lower ball joints to the steering knuckles.
  154.  
  155. Install the right and left stabilizer shaft links to the stabilizer shaft.
  156.  
  157. Install the right and left steering linkage outer tie rod ends to the steering knuckles.
  158.  
  159. Connect all engine electrical connectors.
  160.  
  161. Connect the negative battery extension cable.
  162.  
  163. Connect the transaxle shift cable.
  164.  
  165. Connect the transaxle cooler lines.
  166.  
  167. Connect the steering intermediate shaft to the steering gear.
  168.  
  169. Install a NEW pinch bolt to the steering intermediate shaft. Tighten to 25 ft. lbs. (34 Nm).
  170.  
  171. Install the front tires.
  172.  
  173. Install the exhaust flexible pipe.
  174.  
  175. Install the radiator outlet hose.
  176.  
  177. Lower the vehicle.
  178.  
  179. Install the radiator inlet hose.
  180.  
  181. Connect the outlet coolant heater hose to the engine.
  182.  
  183. Connect the inlet coolant heater hose to the engine.
  184.  
  185. Install the coolant recovery reservoir.
  186.  
  187. Install the A/C compressor discharge hose assembly to the compressor.
  188.  
  189. Install the A/C compressor suction hose assembly to the compressor.
  190.  
  191. Connect the engine fuel hose/pipe to the chassis fuel hose/pipe.
  192.  
  193. Connect the EVAP hose/pipe to the EVAP canister purge solenoid valve.
  194.  
  195. Install the air cleaner assembly.
  196.  
  197. Connect the brake booster vacuum hose to the intake manifold.
  198.  
  199. Position the clamp on the brake booster vacuum hose connection.
  200.  
  201. Install the fuel injector sight shield.
  202.  
  203. Fill the engine with engine oil.
  204.  
  205. Fill the engine with coolant.
  206.  
  207. Check the transaxle fluid level.
  208.  
  209. Charge the AC system.
  210.  
  211. Cycle the ignition ON for 5 seconds then OFF for 10 seconds. Repeat cycling twice.
  212.  
  213. Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds.
  214.  
  215. If the engine does not start, repeat the steps. Top of Form
  216.  

 
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