Caliber 2007

Engine

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Removal & Installation



  1. Drain the engine oil.
  2.  
  3. Drain the cooling system.
  4.  
  5. Properly relieve the fuel system pressure.
  6.  
  7. Remove the hood.
  8.  
  9. Remove the engine appearance cover.
  10.  
  11. Remove the air intake assembly.
  12.  
  13. Disconnect both cables from the battery.
  14.  
  15. Remove the battery and battery tray.
  16.  
  17. Remove the coolant reservoir.
  18.  
  19. Remove the power steering reservoir.
  20.  
  21. Remove the windshield washer reservoir.
  22.  
  23. Remove the coolant hoses from coolant adapter.
  24.  
  25. Remove the grill closure panel.
  26.  
  27. Remove the upper radiator hose support.
  28.  
  29. Disconnect the engine electrical connectors and reposition harness.
  30.  
  31. Remove the air intake tube from throttle body.
  32.  
  33. Disconnect the fuel line from fuel rail.
  34.  
  35. Remove the vacuum lines from throttle body and intake manifold.
  36.  
  37. Remove the wiring harness from the intake.
  38.  
  39. Remove the throttle body support bracket.
  40.  
  41. Disconnect the electronic throttle control and manifold flow control valve electrical connectors.
  42.  
  43. Remove the PCV hose, and make-up air hose from valve cover.

    Click image to see an enlarged view

    Fig. Location of the Ignition Coil electrical connectors (1), make-up air hose (2), fuel line (3), fuel injector electrical connectors (4), and PCV hose (5)-2.0L & 2.4L Engines

  44.  
  45. Remove the dipstick.
  46.  
  47. Remove the intake manifold mounting bolts and remove the intake manifold. For additional information, refer to the following section, "Intake Manifold, Removal & Installation.-
  48.  
  49. Disconnect electrical connectors and reposition harness.
  50.  
  51. Remove the accessory drive belt. For additional information, refer to the following section, "Accessory Drive Belt, Removal & Installation.-
  52.  
  53. Remove the power steering line support at engine mount and exhaust manifold.
  54.  
  55. Remove the power steering pump and set aside.
  56.  
  57. Remove the upper idler pulley.
  58.  
  59. Remove the ground strap near right tower.
  60.  
  61. Raise and safely support the vehicle.
  62.  
  63. Remove the right front wheel.
  64.  
  65. Remove the engine splash shield.
  66.  
  67. Remove the torque converter inspection cover and matchmark the torque converter to the flywheel.
  68.  
  69. Remove the torque converter bolts.
  70.  
  71. Remove the lower bellhousing mounting bolts.
  72.  
  73. Remove the A/C compressor mounting bolts.
  74.  
  75. Remove the alternator and lower idler pulley.
  76.  
  77. Disconnect the crankshaft position (CKP) sensor electrical connector and remove the sensor.
  78.  
  79. Remove the exhaust variable valve timing solenoid.
  80.  
  81. Install an engine lift chain as shown to cylinder head.

    Click image to see an enlarged view

    Fig. Install an engine lift chain (1) to the cylinder head as shown.

  82.  
  83. Connect the chain to the rear engine lift hook.
  84.  
  85. Install engine lifting crane.
  86.  
  87. Remove the right engine mount through-bolt.
  88.  
  89. Remove the engine mount adapter retaining bolts and the mount adapter.

    Click image to see an enlarged view

    Fig. Remove the right engine mount through-bolt (4), mount adapter retaining bolts (3) and mount adapter (2)-2.0L & 2.4L Engine removal

  90.  
  91. Carefully lift the engine from engine compartment.
  92.  

To install:

  1. Position the engine assembly over the vehicle and slowly lower the engine into place.
  2.  
  3. Continue lowering engine until the engine/transaxle assembly are aligned to the mounting locations.
  4.  
  5. Install the engine mount adapter and tighten bolts. Install the mount through-bolt and tighten all bolts to 87 ft. lbs. (118 Nm).
  6.  
  7. Remove the engine lift chain.
  8.  
  9. Install the oil control valve.
  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Install the A/C compressor.
  14.  
  15. Install the exhaust manifold and heat shields.
  16.  
  17. Install the oxygen sensor and connect the electrical connector.
  18.  
  19. Install the crankshaft position sensor and connect connector.
  20.  
  21. Install the manifold to exhaust pipe bolts and tighten bolts.
  22.  
  23. Install the alternator.
  24.  
  25. Install lower bell housing bolts and tighten bolts.
  26.  
  27. Align the torque converter and flex plate matchmark. Install torque converter bolts and tighten.
  28.  
  29. Install the torque converter inspection cover.
  30.  
  31. Install the crankshaft damper, using Special Tool 9707 Damper holder. Apply clean engine oil to the crankshaft damper bolt threads and between bolt head and washer. Tighten bolt to 155 ft. lbs. (210 Nm).
  32.  
  33. Install the right engine splash shield.
  34.  
  35. Install the wheel.
  36.  
  37. Install the coolant hose to the oil cooler.
  38.  
  39. Install a new oil filter.
  40.  
  41. Lower the vehicle.
  42.  
  43. Install the upper idler pulley.
  44.  
  45. Install the coolant adapter assembly.
  46.  
  47. Install the ground strap near the right strut tower.
  48.  
  49. Install the power steering line support bracket and install the power steering pump.
  50.  
  51. Install the accessory drive belt.
  52.  
  53. Connect the electrical connectors at block ground, starter, A/C compressor, knock sensor, oil pressure sensor, generator, coolant temperature sensor at block, and block heater (if equipped).
  54.  
  55. Install the intake manifold
  56.  
  57. Install the throttle body support bracket and wiring harness retainer.
  58.  
  59. Install the dipstick.
  60.  
  61. Install the PCV hose to valve cover and make-up air hose.
  62.  
  63. Connect the manifold flow control valve and electronic throttle control electrical connectors.
  64.  
  65. Install the vacuum lines to the throttle body and intake manifold.
  66.  
  67. Install the intake air tube to the throttle body.
  68.  
  69. Connect the ignition coil electrical connectors.
  70.  
  71. Connect the injector electrical connectors.
  72.  
  73. Connect the fuel line to fuel rail.
  74.  
  75. Connect the intake and exhaust oil control valve electrical connectors.
  76.  
  77. Install the grill trim panel.
  78.  
  79. Install the upper radiator support bracket.
  80.  
  81. Connect the coolant temperature sensor.
  82.  
  83. Connect the capacitor electrical connector.
  84.  
  85. Install the coolant hoses at coolant adapter.

    Click image to see an enlarged view

    Fig. Location of the coolant temperature sensor (1), capacitor electrical connector (2) and coolant hoses connected to the coolant adapter (3)-2.0L & 2.4L Engines

  86.  
  87. Install the coolant reservoir and connect hose.
  88.  
  89. Install the battery tray and battery.
  90.  
  91. Connect the battery cables.
  92.  
  93. Install the air intake assembly.
  94.  
  95. Refill the cooling system to the correct level.
  96.  
  97. Refill the engine with oil to the correct level.
  98.  
  99. Install the engine appearance cover.
  100.  
  101. Install the hood.
  102.  
  103. Start the engine and check for leaks.
  104.  

 
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