For 1990-2009 cars

## Engine Replacement AT_6T45

#### Special Tools

• | EN 412 Engine Stand

• | CH 807 Closure Plugs

• | CH 904 XXX

• | CH 6015 Closure Plugs

• | CH 49290 Mounting Engine/Transmission

• | CH 49289 Centering Adapter

For equivalent regional tools, refer to Special Tools .

### Removal Procedure

1. Remove the lower intermediate steering shaft bolt. Refer to Intermediate Steering Shaft Replacement .
2. Open the hood.
3. Remove the engine cover. Refer to Engine Cover Replacement .
4. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
5. Remove the battery tray. Refer to Battery Tray Replacement .
6. Remove the windshield washer solvent container filler tube (1).
7. Remove the front compartment fuse block cover (1).
8. Remove the 3 front compartment fuse block bolts (1).
9. Remove the front compartment fuse block (2).
10. Unclip the 3 wiring harness plugs (3).
11. Disconnect the wiring harness plug from the front compartment fuse block.
12. Remove the 3 ground nuts (1) and put the 4 wiring harness (2) aside.
13. Disconnect the 2 wiring harness plugs (1, 2).
14. Remove the air cleaner housing. Refer to Air Cleaner Assembly Replacement .
15. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .
16. Remove the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
17. Drain the cooling system. Refer to Cooling System Draining and Filling .
18. Unclip the radiator surge tank.
19. Put the radiator surge tank aside.
20. Disconnect the transmission range selector lever cable terminal (1) from the transmission manual shift lever pin.
21. Press the locking tabs inward in order to release the transmission range selector lever cable (2) from the cable bracket.
22. Remove the heater inlet hose from the bulkhead. Refer to Heater Inlet Hose Replacement .
23. Remove the heater outlet hose from the bulkhead. Refer to Heater Outlet Hose Replacement .
24. Remove power steering fluid reservoir bolt.
25. Unclip power steering fluid reservoir and support it on the engine.
26. Remove the fuel return front hose clamp (3).
27. Remove the fuel return front hose (2) from the fuel return pipe to fuel injection pump.
28. Close the vents with the CH 807 closure plugs .
29. Disconnect the fuel feed pipe (1) from the fuel feed pipe connector (4).
30. Close the vents with the CH 6015 closure plugs .
31. Disconnect the exhaust pressure differential sensor wiring harness plug.
32. Disconnect the exhaust temperature sensor wiring harness plug.
33. Remove A/C compressor and condenser hose nut (1) from refrigerant hose (2).
34. Remove the air conditioning evaporator hose assembly nut from the air conditioning condenser.
35. Remove the front flex pipe. Refer to Exhaust Flexible Pipe Replacement .
36. Lower the vehicle by its half height.
37. Remove the upper stabilizer shaft link from the absorber on both sides. Refer to Stabilizer Shaft Link Replacement .
38. Remove steering linkage outer tie rod from the steering knuckle on both sides. Refer to Steering Linkage Outer Tie Rod Replacement .
39. Remove the front lower control arm from the steering knuckle. Refer to Lower Control Arm Replacement .
40. Remove the front wheel shafts from the wheel hubs. Refer to Front Wheel Drive Shaft Replacement - Right Side .
41. Raise the vehicle by its half height.
42. Remove the wheel speed sensor wiring harness (2) from the frame on both sides.

43. Remove the wiring harness retainers (3) from the frame and the lower control arm.
44. Remove wiring harness engine cooling fan.

• | Disconnect the 4 wiring harness connector engine cooling fan (2).

• | Remove engine coolant fan wiring harness relay block (1).

• | Disconnect wiring harness connector air conditioning refrigerant pressure sensor (3).

45. Install the CH 49290 mounting . Refer to Engine/Transmission Mounting .
46. Remove the engine mount - right side. Refer to Engine Mount Replacement - Right Side .
47. Remove the transmission mount replacement - left side. Refer to Transmission Mount Replacement - Left Side .
48. Remove the left and right guide pin from the CH 49290 mounting .
49. Raise the CH 904 underframe and CH 49289 adapter with the hydraulic jack until it contact the frame.

Note: Positioning pins (2 ,3) of CH 49289 adapter MUST stick into holes of drivetrain frame.

50. Check if wheel alignment is required.

Move out position pins (1) and try to insert into underbody holes.

If guide pins can NOT be insert, the Wheel Alignment Measurement is required after installation of drive train frame.

51. Remove and discard the front frame bolts (2).
52. Remove and discard the rear frame bolts (3).
53. Remove the frame reinforcements (4).
54. Lower the frame (1) with the engine transmission unit off the vehicle.
55. Remove the right wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Right Side .
56. Remove the left wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side .
57. Install suitable cable at the 3 engine lift brackets.
58. Install a suitable engine lifting device to the cable.
59. Extend the engine lifting device until the steel cable are slightly tensioned.
60. Remove A/C compressor and condenser hose nut (1) from A/C condenser (2).
61. Loosen the radiator outlet hose clamp (5).
62. Remove the radiator outlet hose (3) from the radiator outlet pipe (4).
63. Loosen the radiator inlet hose clamp (2).
64. Remove the radiator inlet hose (3) from the radiator (1).
65. Remove the transmission fluid cooler inlet pipe replacement. Refer to Transmission Fluid Cooler Inlet Pipe Replacement .
66. Remove the transmission fluid cooler outlet pipe replacement. Refer to Transmission Fluid Cooler Outlet Pipe Replacement .
67. Remove the front transaxle mount through bolt (1).
68. Remove the transmission bracket mount to mount through bolt (1).
69. Put the engine transmission unit down on a wooden pallet.
70. Loosen the 8 transmission bolts and remove 7 of them. Refer to Transmission Replacement .

Note: Two mechanics required.

71. Remove the last transmission bolt and the transmission.
72. Install the engine to the EN 412 engine stand
73. Transfer parts as needed.

### Installation Procedure

1. Remove the engine from the EN 412 engine stand
2. Put the engine down on a wooden pallet.

Note: Two mechanics required.

3. Install the transmission and one transmission bolt.
4. Install the 7 transmission bolts.

Caution: Refer to Fastener Caution in the Preface section.

5. Tighten the 8 transmission bolts. Refer to Transmission Replacement .
6. Place the engine transmission unit into the front frame.
7. Install the transmission bracket mount to mount through bolt (1) and tighten to 100 N·m (74 lb ft) .
8. Install the transaxle mount through bolt (1) and tighten to 58 N·m (43 lb ft) .
9. Remove the cable from the 3 engine lift brackets.
10. Install the transmission fluid cooler inlet pipe replacement. Refer to Transmission Fluid Cooler Inlet Pipe Replacement .
11. Install the transmission fluid cooler outlet pipe replacement. Refer to Transmission Fluid Cooler Outlet Pipe Replacement .
12. Install the radiator inlet hose (3) to the radiator (1).
13. Install the radiator inlet hose clamp (2).
14. Install the radiator outlet hose (3) to the radiator outlet pipe (4).
15. Install the radiator outlet hose clamp (5).

Note: Use a NEW O-ring seal. Refer to O-Ring Replacement .

16. Install the air conditioning evaporator hose assembly nut from the air conditioning condenser and tighten to 19 N·m (14 lb ft) .

Note: Use a NEW O-ring seal. Refer to O-Ring Replacement .

17. Install A/C compressor and condenser hose nut (1) to A/C condenser (2). Tighten nut to 19 N·m (14 lb ft) .
18. Install the right wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Right Side .
19. Install the left wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side .
20. Raise the frame with the engine transmission unit to the vehicle.

Note: Positioning pins (1) of CH 49289 adapter MUST be extended in order to guide into underbody holes.

21. Install the frame reinforcements (4).
22. Install front frame bolts. Hand tighten ONLY.
23. Install reinforcement bolts. Hand tighten ONLY.

Note: Do NOT reuse old bolts.

24. Tighten the rear frame bolts (3) and tighten to 90 N·m (67 lb ft) +130 degrees .

Note: Do NOT reuse old bolts.

25. Tighten the front frame bolts (2) and tighten to 120 N·m (89 lb ft) +130 degrees .
26. Lower the CH-49289 with the hydraulic jack until it is removable.
27. Install the left and right guide pin at the CH 49290 mounting .
28. Install the engine mount - right side. Refer to Engine Mount Replacement - Right Side .
29. Install the transmission mount replacement - left side. Refer to Transmission Mount Replacement - Left Side .
30. Remove the CH 49290 mounting . Refer to Engine/Transmission Mounting .
31. Install wiring harness engine cooling fan.

• | Connect wiring harness connector air conditioning refrigerant pressure sensor (3).

• | Install engine coolant fan wiring harness relay block (1).

• | Connect the 4 harness connector engine cooling fan (2).

32. Install the wheel speed sensor wiring harness (2) to the frame on both sides.

Install the wiring harness retainers (3) to the frame and the lower control arm.

33. Lower the vehicle by its half height.
34. Install the front wheel shafts to the wheel hubs. Refer to Front Wheel Drive Shaft Replacement - Right Side .
35. Install the front lower control arm to the steering knuckle. Refer to Lower Control Arm Replacement .
36. Install the steering linkage outer tie rod to the steering knuckle on both sides. Refer to Steering Linkage Outer Tie Rod Replacement .
37. Install the upper stabilizer shaft link to the absorber on both sides. Refer to Stabilizer Shaft Link Replacement .
38. Raise the vehicle by its half height.
39. Install the exhaust flexible pipe. Refer to Exhaust Flexible Pipe Replacement .

Note: Use a NEW O-ring seal. Refer to O-Ring Replacement .

40. Install A/C compressor and condenser hose nut (1) to refrigerant hose (2) . Tighten nut to 19 N·m (14 lb ft) .
41. Connect the exhaust temperature sensor wiring harness plug.
42. Connect the exhaust pressure differential sensor wiring harness plug.
43. Remove the CH 6015 closure plugs .
44. Connect the fuel feed pipe (1) from the fuel feed pipe connector (4).
45. Remove the CH 807 closure plugs .
46. Install the fuel return front hose (2) from the fuel return pipe to fuel injection pump.
47. Install the fuel return front hose clamp (3).
48. Clip in the power steering fluid reservoir.
49. Install the power steering fluid reservoir bolt and tighten to 9 N·m (80 lb in) .
50. Install the heater inlet hose to the bulkhead. Refer to Heater Inlet Hose Replacement .
51. Install the heater outlet hose to the bulkhead. Refer to Heater Outlet Hose Replacement .
52. Install the transmission range selector lever cable (2) to the cable bracket.
53. Connect the transmission range selector lever cable terminal (1) to the transmission manual shift lever pin.
54. Check the range selector cable adjustment. Refer to Range Selector Lever Cable Adjustment .
55. Clip in the radiator surge tank.
56. Fill the cooling system. Refer to Cooling System Draining and Filling .
57. Install the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
58. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .
59. Install the air cleaner housing. Refer to Air Cleaner Assembly Replacement .
60. Connect the 2 wiring harness plugs (1, 2).
61. Install the 4 wiring harness (2).
62. Install the 3 ground nuts (1) and tighten to 9 N·m (80 lb in)
63. Clip in the 3 wiring harness plugs (3).
64. Connect the wiring harness plug to the front compartment fuse block.
65. Install the front compartment fuse block (2).
66. Install the 3 front compartment fuse block bolts (1) and tighten to XX N·m (XX lb in) .
67. Install the front compartment fuse block cover (1).
68. Install the windshield washer solvent container filler tube (1).
69. Fill the transmission with fluid. Refer to Transmission Fluid Check .
70. Install the battery tray. Refer to Battery Tray Replacement .
71. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
72. Check the oil level and fill NEW engine oil up if necessary.
73. Install the engine cover. Refer to Engine Cover Replacement .
74. Close the hood.
75. Install the lower intermediate steering shaft bolt. Refer to Intermediate Steering Shaft Replacement .

## Engine Replacement D33

#### Special Tools

• | EN 412 Engine Stand

• | CH 807 Closure Plugs

• | CH 904 XXXX

• | EN 6015 Closure Plugs

• | CH 49289 Centering Adapter

• | CH 49290 Mounting Engine/Transmission

For equivalent regional tools, refer to Special Tools .

### Removal Procedure

1. Remove the lower intermediate steering shaft bolt. Refer to Intermediate Steering Shaft Replacement .
2. Open the hood.
3. Remove the engine cover. Refer to Engine Cover Replacement .
4. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
5. Remove the battery tray. Refer to Battery Tray Replacement .
6. Remove the windshield washer solvent container filler tube (1).
7. Remove the front compartment fuse block cover (1).
8. Remove the 3 front compartment fuse block bolts (1).
9. Remove the front compartment fuse block (2).
10. Unclip the 3 wiring harness plugs (3).
11. Disconnect the wiring harness plug from the front compartment fuse block.
12. Remove the 3 ground nuts (1) and put the 4 wiring harness (2) aside.
13. Disconnect the 2 wiring harness plugs (1, 2).
14. Remove the air cleaner housing. Refer to Air Cleaner Assembly Replacement .
15. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .
16. Remove the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
17. Drain the cooling system. Refer to Cooling System Draining and Filling .
18. Unclip the radiator surge tank.
19. Put the radiator surge tank aside.
20. Remove the 2 manual transmission selector lever cable from the transmission. Refer to Manual Transmission Shift Lever and Selector Lever Cable Replacement .
21. Remove the heater inlet hose from the bulkhead. Refer to Heater Inlet Hose Replacement .
22. Remove the heater outlet hose from the bulkhead. Refer to Heater Outlet Hose Replacement .
23. Remove power steering fluid reservoir bolt.
24. Unclip power steering fluid reservoir and support it on the engine.
25. Remove the fuel return front hose clamp (3).
26. Remove the fuel return front hose (2) from the fuel return pipe to fuel injection pump.
27. Close the vents with the CH 807 closure plugs .
28. Disconnect the fuel feed pipe (1) from the fuel feed pipe connector (4).
29. Close the vents with the EN 6015 closure plugs .
30. Disconnect the exhaust pressure differential sensor wiring harness plug.
31. Disconnect the exhaust temperature sensor wiring harness plug.
32. Remove A/C compressor and condenser hose nut (1) from refrigerant hose (2).
33. Remove the air conditioning evaporator hose assembly nut from the air conditioning condenser.
34. Remove the front flex pipe. Refer to Exhaust Flexible Pipe Replacement .
35. Lower the vehicle by its half height.
36. Remove the upper stabilizer shaft link from the absorber on both sides. Refer to Stabilizer Shaft Link Replacement .
37. Remove steering linkage outer tie rod from the steering knuckle on both sides. Refer to Steering Linkage Outer Tie Rod Replacement .
38. Remove the front lower control arm from the steering knuckle. Refer to Lower Control Arm Replacement .
39. Remove the front wheel shafts from the wheel hubs. Refer to Front Wheel Drive Shaft Replacement - Right Side .
40. Raise the vehicle by its half height.
41. Remove the wheel speed sensor wiring harness (2) from the frame on both sides.
42. Remove the wiring harness retainers (3) from the frame and the lower control arm.
43. Remove wiring harness engine cooling fan.

• | Disconnect the 4 wiring harness connector engine cooling fan (2).

• | Remove engine coolant fan wiring harness relay block (1).

• | Disconnect wiring harness connector air conditioning refrigerant pressure sensor (3).

44. Install the CH 49290 mounting . Refer to Engine/Transmission Mounting .
45. Remove the engine mount - right side. Refer to Engine Mount Replacement - Right Side .
46. Remove the transmission mount - left side. Refer to Transmission Mount Replacement .
47. Remove the left and right guide pin from the CH 49290 mounting .
48. Raise the CH 904 underframe and CH 49289 adapter with the hydraulic jack until it contact the frame.

Note: Positioning pins (2 ,3) of CH 49289 adapter MUST stick into holes of drivetrain frame.

49. Check if wheel alignment is required.

Move out position pins (1) and try to insert into underbody holes.

If guide pins can NOT be insert, the Wheel Alignment Measurement is required after installation of drive train frame.

50. Remove and discard the front frame bolts (2).
51. Remove and discard the rear frame bolts (3).
52. Remove the frame reinforcements (4).
53. Lower the frame (1) with the engine transmission unit off the vehicle.
54. Remove the right wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Right Side .
55. Remove the left wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side .
56. Install suitable cable at the 3 engine lift brackets.
57. Install a suitable engine lifting device to the cable.
58. Extend the engine lifting device until the steel cable are slightly tensioned.
59. Remove A/C compressor and condenser hose nut (1) from A/C condenser (2).
60. Loosen the radiator outlet hose clamp (5).
61. Remove the radiator outlet hose (3) from the radiator outlet pipe (4).
62. Loosen the radiator inlet hose clamp (2).
63. Remove the radiator inlet hose (3) from the radiator (1).
64. Remove the front transaxle mount through bolt (1).
65. Remove the transmission bracket mount to mount through bolt (1).
66. Put the engine transmission unit down on a wooden pallet.
67. Loosen the 8 transmission bolts and remove 7 of them. Refer to Transmission Replacement .

Note: Two mechanics required.

68. Remove the last transmission bolt and the transmission.
69. Install the engine to the EN 412 engine stand .
70. Transfer parts as needed.

### Installation Procedure

1. Remove the engine from the EN 412 engine stand
2. Put the engine down on a wooden pallet.

Note: Two mechanics required.

3. Install the transmission and one transmission bolt.
4. Install the 7 transmission bolts.

Caution: Refer to Fastener Caution in the Preface section.

5. Tighten the 8 transmission bolts. Refer to Transmission Replacement .
6. Place the engine transmission unit into the front frame.
7. Install the transmission bracket mount to mount through bolt (1) and tighten to 100 N·m (74 lb ft) .
8. Install the transaxle mount through bolt (1) and tighten to 58 N·m (43 lb ft) .
9. Remove the cable from the 3 engine lift brackets.
10. Install the radiator inlet hose (3) to the radiator (1).
11. Install the radiator inlet hose clamp (2).
12. Install the radiator outlet hose (3) to the radiator outlet pipe (4).
13. Install the radiator outlet hose clamp (5).

Note: Use a NEW O-ring seal. Refer to O-Ring Replacement .

14. Install the air conditioning evaporator hose assembly nut from the air conditioning condenser and tighten to 19 N·m (14 lb ft) .

Note: Use a NEW O-ring seal. Refer to O-Ring Replacement .

15. Install A/C compressor and condenser hose nut (1) to A/C condenser (2). Tighten nut to 19 N·m (14 lb ft) .
16. Install the right wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Right Side .
17. Install the left wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side .
18. Raise the frame with the engine transmission unit to the vehicle.

Note: Positioning pins (1) of CH 49289 adapter MUST be extended in order to guide into underbody holes.

19. Install the frame reinforcements (4).
20. Install front frame bolts. Hand tighten ONLY.
21. Install reinforcement bolts. Hand tighten ONLY.

Note: Do NOT reuse old bolts.

22. Tighten the rear frame bolts (3) and tighten to 90 N·m (67 lb ft) + 130 degrees .

Note: Do NOT reuse old bolts.

23. Tighten the front frame bolts (2) and tighten to 120 N·m (89 lb ft) + 130 degrees .
24. Lower the CH-49289 adapter with the hydraulic jack until it is removable.
25. Install the left and right guide pin at the CH 49290 mounting .
26. Install the engine mount - right side. Refer to Engine Mount Replacement - Right Side .
27. Install the transmission mount - left side. Refer to Transmission Mount Replacement .
28. Remove the CH 49290 mounting . Refer to Engine/Transmission Mounting .
29. Install wiring harness engine cooling fan.

• | Connect wiring harness connector air conditioning refrigerant pressure sensor (3).

• | Install engine coolant fan wiring harness relay block (1).

• | Connect the 4 harness connector engine cooling fan (2).

30. Install the wheel speed sensor wiring harness (2) to the frame on both sides.

Install the wiring harness retainers (3) to the frame and the lower control arm.

31. Lower the vehicle by its half height.
32. Install the front wheel shafts to the wheel hubs. Refer to Front Wheel Drive Shaft Replacement - Right Side .
33. Install the front lower control arm to the steering knuckle. Refer to Lower Control Arm Replacement .
34. Install the steering linkage outer tie rod to the steering knuckle on both sides. Refer to Steering Linkage Outer Tie Rod Replacement .
35. Install the upper stabilizer shaft link to the absorber on both sides. Refer to Stabilizer Shaft Link Replacement .
36. Raise the vehicle by its half height.
37. Install the exhaust flexible pipe. Refer to Exhaust Flexible Pipe Replacement .

Note: Use a NEW O-ring seal. Refer to O-Ring Replacement .

38. Install A/C compressor and condenser hose nut (1) to refrigerant hose (2) . Tighten nut to 19 N·m (14 lb ft) .
39. Connect the exhaust temperature sensor wiring harness plug.
40. Connect the exhaust pressure differential sensor wiring harness plug.
41. Remove the EN 6015 closure plugs .
42. Connect the fuel feed pipe (1) from the fuel feed pipe connector (4).
43. Remove the CH 807 closure plugs .
44. Install the fuel return front hose (2) from the fuel return pipe to fuel injection pump.
45. Install the fuel return front hose clamp (3).
46. Clip in the power steering fluid reservoir.
47. Install the power steering fluid reservoir bolt and tighten to 9 N·m (80 lb in) .
48. Install the heater inlet hose to the bulkhead. Refer to Heater Inlet Hose Replacement .
49. Install the heater outlet hose to the bulkhead. Refer to Heater Outlet Hose Replacement .
50. Install the 2 manual transmission selector lever cable to the transmission. Refer to Manual Transmission Shift Lever and Selector Lever Cable Replacement .
51. Clip in the radiator surge tank.
52. Fill the cooling system. Refer to Cooling System Draining and Filling .
53. Install the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
54. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .
55. Install the air cleaner housing. Refer to Air Cleaner Assembly Replacement .
56. Connect the 2 wiring harness plugs (1, 2).
57. Install the 4 wiring harness (2).
58. Install the 3 ground nuts (1) and tighten to 9 N·m (80 lb in) .
59. Clip in the 3 wiring harness plugs (3).
60. Connect the wiring harness plug to the front compartment fuse block.
61. Install the front compartment fuse block (2).
62. Install the 3 front compartment fuse block bolts (1) and tighten to XX N·m (XX lb in) .
63. Install the front compartment fuse block cover (1).
64. Install the windshield washer solvent container filler tube (1).
65. Install the battery tray. Refer to Battery Tray Replacement .
66. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
67. Check the oil level and fill NEW engine oil up if necessary.
68. Install the engine cover. Refer to Engine Cover Replacement .
69. Close the hood.
70. Install the lower intermediate steering shaft bolt. Refer to Intermediate Steering Shaft Replacement .