For 1990-2009 cars

## Engine Replacement MT_D16

#### Special Tools

• | EN 412 Engine Stand

• | CH 807 Closure Plugs

• | CH 904 Underframe

• | 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. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
4. Remove the battery tray. Refer to Battery Tray Replacement
5. Remove the windshield washer solvent container filler tube (1).
6. Remove the front compartment fuse block cover (1).
7. Remove the 3 front compartment fuse block bolts (1).
8. Remove the front compartment fuse block (2).
9. Unclip the 3 wiring harness plugs (3).
10. Disconnect the wiring harness plug from the front compartment fuse block.
11. Remove the 3 ground nuts (1) and put the 3 wiring harness (2) aside.
12. Disconnect the 2 wiring harness plugs (1, 2).
13. Remove the air cleaner housing. Refer to Air Cleaner Assembly Replacement
14. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement.
15. Remove the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
16. Drain the cooling system. Refer to Cooling System Draining and Filling.
17. Unclip the radiator surge tank.
18. Put the radiator surge tank aside.
19. Remove the manual transmission shift lever and selector lever cable from the transmission. Refer to Manual Transmission Shift Lever and Selector Lever Cable Replacement
20. Remove the heater inlet hose from the bulkhead. Refer to Heater Inlet Hose Replacement.
21. Remove the heater outlet hose from the bulkhead. Refer to Heater Outlet Hose Replacement.
22. Disconnect the booster vacuum pipe (1) from the intake manifold.
23. Place collecting basin underneath.
24. Disconnect the clutch actuator cylinder front pipe. Refer to Clutch Actuator Cylinder Front Pipe Replacement.
25. Disconnect the fuel tank vent pipe from the evaporative emission vent valve.
26. Close the vents with the CH 807 closure plugs .
27. Disconnect the fuel filler pipe from the multiport fuel injection fuel rail.
28. Close the vents with the CH 807 closure plugs .
29. Remove power steering fluid reservoir bolt.
30. Unclip power steering fluid reservoir and support it on the engine.
31. Remove A/C compressor and condenser hose nut (1) from A/C condenser (2).
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. Unclip the Radiator outlet hose from the radiator.
35. Remove the radiator support bracket. Refer to Radiator Support Bracket Replacement.
36. Raise the vehicle by its full height. Refer to Lifting and Jacking the Vehicle.
37. Remove the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement.
38. Lower the vehicle by its half height.
39. Remove the upper stabilizer shaft link from the absorber on both sides. Refer to LINK 47441.
40. Remove steering linkage outer tie rod from the steering knuckle on both sides. Refer to Steering Linkage Outer Tie Rod Replacement.
41. Remove the front lower control arm from the steering knuckle. Refer to Lower Control Arm Replacement.
42. Remove the front wheel shafts from the wheel hubs. Refer to Front Wheel Drive Shaft Replacement - Right Side and Front Wheel Drive Shaft Replacement - Left Side.
43. Disconnect the wheel speed sensors on both sides.
44. Raise the vehicle by its half height.
45. Remove the wheel speed sensor wiring harness retainers from the frame.
46. Unclip the 2 engine coolant fan wiring harness (1, 2) from the frame.
47. Remove the exhaust flexible pipe. Refer to Exhaust Flexible Pipe Replacement
48. Install the mounting engine / transmission. Refer to Engine/Transmission Mounting.
49. Remove the engine mount - right side. Refer to Engine Mount Replacement.
50. Remove the engine mount - left side. Refer to Transmission Mount Replacement.
51. 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.

52. 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.

53. Remove and discard the front frame bolts (2).
54. Remove and discard the rear frame bolts (3).
55. Remove the frame reinforcements (4).
56. Lower the frame (4) with the engine transmission unit off the vehicle.
57. Remove the right wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Right Side
58. Remove the left wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side
59. Remove the power steering fluid reservoir outlet hose. Refer to Power Steering Fluid Reservoir Outlet Hose Replacement.
60. Loosen the radiator outlet hose clamp (2).
61. Remove the radiator outlet hose (3) from the water pump (1).
62. Loosen the radiator inlet hose clamp (4).
63. Remove the radiator inlet hose (3) from the engine coolant thermostat (5).
64. Install suitable cable at the 3 engine lift brackets.
65. Install a suitable engine lifting device to the cable.
66. Extend the engine lifting device until the steel cable are slightly tensioned.
67. Remove the front transmission 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 transmission 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 engine coolant thermostat (5).
11. Install the radiator inlet hose clamp (4).
12. Install the radiator outlet hose (3) to the water pump (1).
13. Install the radiator outlet hose clamp (2).
14. Install the power steering fluid reservoir outlet hose. Refer to Power Steering Fluid Reservoir Outlet Hose Replacement.
15. Install the right wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Right Side.
16. Install the left wheel drive shaft from the transmission. Refer to Front Wheel Drive Shaft Replacement - Left Side.

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

17. Raise the frame (1) with the engine transmission unit to the vehicle.
18. Install the frame reinforcements (4).
19. Install front frame bolts (2). Hand tighten ONLY.
20. Install reinforcement bolts (3). Hand tighten ONLY.

Note: Do NOT reuse old bolts.

21. Tighten the rear frame bolts (2) and tighten to 90 N·m (67 lb ft) +130 degrees.

Note: Do NOT reuse old bolts.

22. Tighten the front frame bolts (1) and tighten to 120 N·m (89 lb ft) + 130 degrees.
23. Lower the CH-49289 with the hydraulic jack until it is removable.
24. Install the engine mount - right side. Refer to Engine Mount Replacement.
25. Install the engine mount - left side. Refer to Transmission Mount Replacement.
26. Remove the mounting engine / transmission. Refer to Engine/Transmission Mounting.
27. Install the exhaust flexible pipe. Refer to Exhaust Flexible Pipe Replacement.
28. Clip the 2 engine coolant fan wiring harness (1, 2) into the frame.
29. Lower the vehicle by its half height.
30. Install the wheel speed sensor wiring harness retainers from the frame.
31. Connect the wheel speed sensor on both sides.
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 LINK 47441.
36. Raise the vehicle by its half height.
37. Install the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement.
38. Check the transmission fluid level. Refer to Transmission Fluid Level Inspection.
39. Lower the vehicle by its full height.
40. Install the radiator support bracket. Refer to Radiator Support Bracket Replacement.
41. Clip the Radiator outlet hose into the radiator.

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

42. 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.

43. Install A/C compressor and condenser hose nut (1) to A/C condenser (2). Tighten the nut to 19 N·m (14 lb ft).

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

44. Install A/C compressor and condenser hose nut (1) to refrigerant hose (2). Tighten the nut to 19 N·m (14 lb ft).
45. Clip in the power steering fluid reservoir.
46. Install power steering fluid reservoir bolt and tighten to 9 N·m (7 lb in).
47. Remove the CH 807 closure plugs .
48. Connect the fuel filler pipe to the multiport fuel injection fuel rail.
49. Remove the CH 807 closure plugs .
50. Connect the fuel tank vent pipe to the evaporative emission vent valve.
51. Remove the heater outlet hose from the bulkhead. Refer to Heater Outlet Hose Replacement.
52. Connect the clutch actuator cylinder front pipe. Refer to Clutch Actuator Cylinder Front Pipe Replacement
53. Bleed the hydraulic clutch system. Refer to Hydraulic Clutch Bleeding.
54. Fill the reservoir with clutch/brake fluid up to the MAX level.
55. Connect the booster vacuum pipe (1) to the intake manifold.
56. Install the heater inlet hose to the bulkhead. Refer to Heater Inlet Hose Replacement.
57. Install the heater outlet hose to the bulkhead. Refer to Heater Outlet Hose Replacement.
58. Install the manual transmission shift lever and selector lever cable to the transmission. Refer to Manual Transmission Shift Lever and Selector Lever Cable Replacement.
59. Clip in the radiator surge tank.
60. Fill the cooling system. Refer to Cooling System Draining and Filling.
61. Install the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
62. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement.
63. Install the air cleaner housing. Refer to Air Cleaner Assembly Replacement.
64. Connect the 2 wiring harness plugs (1, 2).
65. Install the 3 wiring harness (2).
66. Install the 3 ground nuts (1) and tighten to 9 N·m (7 lb in).
67. Clip in the 3 wiring harness plugs (3).
68. Connect the wiring harness plug to the front compartment fuse block.
69. Install the front compartment fuse block (2).
70. Install the 3 front compartment fuse block bolts (1) and tighten to 22 N·m (17 lb ft).
71. Install the front compartment fuse block cover (1).
72. Install the windshield washer solvent container filler tube.
73. Install the battery tray. Refer to Battery Tray Replacement.
74. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging.
75. Check the oil level and fill NEW engine oil up if necessary.
76. Close the hood.
77. Install the lower intermediate steering shaft bolt. Refer to Intermediate Steering Shaft Replacement.

## Engine Replacement AT_6T40

#### Special Tools

• | EN-412 Engine Stand

• | CH-807 Closure Plugs

• | CH 904 Underframe

• | 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. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
4. Remove the battery tray. Refer to Battery Tray Replacement.
5. Remove the windshield washer solvent container filler tube (1).
6. Remove the front compartment fuse block cover (1).
7. Remove the 3 front compartment fuse block bolts (1).
8. Remove the front compartment fuse block (2).
9. Unclip the 3 wiring harness plugs (3).
10. Disconnect the wiring harness plug from the front compartment fuse block.
11. Remove the 3 ground nuts (1) and put the 3 wiring harness (2) aside.
12. Disconnect the 2 wiring harness plugs (1, 2).
13. Remove the air cleaner housing. Refer to Air Cleaner Assembly Replacement.
14. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement.
15. Remove the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
16. Drain the cooling system. Refer to Cooling System Draining and Filling.
17. Unclip the radiator surge tank.
18. Put the radiator surge tank aside.
19. Disconnect the transmission range selector lever cable terminal (1) from the transmission manual shift lever pin.
20. Press the locking tabs inward in order to release the transmission range selector lever cable (2) from the cable bracket.
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. Disconnect the booster vacuum pipe (1) from the intake manifold.
24. Place collecting basin underneath.
25. Disconnect the fuel tank vent pipe from the evaporative emission vent valve.
26. Close the vents with the CH-807 closure plugs .
27. Disconnect the fuel filler pipe from the multiport fuel injection fuel rail.
28. Close the vents with the CH-807 closure plugs .
29. Remove power steering fluid reservoir bolt.
30. Unclip power steering fluid reservoir and support it on the engine.
31. Remove A/C compressor and condenser hose nut (1) from A/C condenser (2).
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. Unclip the Radiator outlet hose from the radiator.
35. Remove the radiator support bracket. Refer to Radiator Support Bracket Replacement.
36. Raise the vehicle by its full height. Refer to Lifting and Jacking the Vehicle.
37. Remove the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement.
38. Lower the vehicle by its half height.
39. Remove the upper stabilizer shaft link from the absorber on both sides. Refer to Stabilizer Shaft Link Replacement.
40. Remove steering linkage outer tie rod from the steering knuckle on both sides. Refer to Steering Linkage Outer Tie Rod Replacement.
41. Remove the front lower control arm from the steering knuckle. Refer to Lower Control Arm Replacement.
42. Remove the front wheel shafts from the wheel hubs. Refer to Front Wheel Drive Shaft Replacement - Right Side.
43. Disconnect the wheel speed sensor on both sides.
44. Raise the vehicle by its half height.
45. Remove the wheel speed sensor wiring harness retainers from the frame.
46. Unclip the 2 engine coolant fan wiring harness (1, 2) from the frame.
47. Remove the exhaust flexible pipe. Refer to Exhaust Flexible Pipe Replacement.
48. Install the mounting engine/transmission. Refer to Engine/Transmission Mounting.
49. Remove the engine mount - right side. Refer to Engine Mount Replacement - Right Side.
50. Remove the engine mount - left side. Refer to Transmission Mount Replacement - Left Side.
51. 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.

52. Check if wheel alignment is required.

Move out 2 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.

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

Note: Two mechanics required.

74. Remove the last transmission bolt and the transmission.
75. Install the engine to the EN-412 engine stand
76. 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 transmission 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 engine coolant thermostat (5).
11. Install the radiator inlet hose clamp (4).
12. Install the radiator outlet hose (3) to the water pump (1).
13. Install the radiator outlet hose clamp (2).
14. Install the power steering fluid reservoir outlet hose. Refer to Power Steering Fluid Reservoir Outlet Hose Replacement.
15. Install the transmission fluid cooler inlet pipe. Refer to Transmission Fluid Cooler Inlet Pipe Replacement.
16. Install the transmission fluid cooler outlet pipe. Refer to Transmission Fluid Cooler Outlet Pipe Replacement.
17. Fill the transmission with fluid. Refer to Transmission Fluid Check.
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.

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

20. Raise the frame (1) with the engine transmission unit to the vehicle.
21. Install the frame reinforcements (4).
22. Install front frame bolts (2). Hand tighten ONLY.
23. Install reinforcement bolts (3). Hand tighten ONLY.

Note: Do NOT reuse old bolts.

24. Tighten the rear frame bolts (2) and tighten to 90 N·m (67 lb ft) + 130 degrees.

Note: Do NOT reuse old bolts.

25. Tighten the front frame bolts (1) and tighten to 120 N·m (89 lb ft) + 130 degrees.
26. Lower the CH-49289 adapter with the hydraulic jack until it is removable.
27. Install the engine mount - right side. Refer to Engine Mount Replacement - Right Side.
28. Install the engine mount - left side. Refer to Transmission Mount Replacement - Left Side.
29. Remove the mounting engine/transmission. Refer to Engine/Transmission Mounting.
30. Install the exhaust flexible pipe. Refer to Exhaust Flexible Pipe Replacement.
31. Clip the 2 engine coolant fan wiring harness (1, 2) into the frame.
32. Lower the vehicle by its half height.
33. Install the wheel speed sensor wiring harness retainers from the frame.
34. Connect the wheel speed sensor on both sides.
35. Install the front wheel shafts to the wheel hubs. Refer to Front Wheel Drive Shaft Replacement - Right Side.
36. Install the front lower control arm to the steering knuckle. Refer to Lower Control Arm Replacement.
37. Install the steering linkage outer tie rod to the steering knuckle on both sides. Refer to Steering Linkage Outer Tie Rod Replacement.
38. Install the upper stabilizer shaft link to the absorber on both sides. Refer to Stabilizer Shaft Link Replacement.
39. Raise the vehicle by its half height.
40. Install the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement.
41. Lower the vehicle by its full height.
42. Clip the Radiator outlet hose into the radiator.
43. Install the radiator support bracket. Refer to Radiator Support Bracket Replacement.

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

44. 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.

45. Install A/C compressor and condenser hose nut (1) to A/C condenser (2). Tighten nut to 19 N·m (14 lb ft).

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

46. Install A/C compressor and condenser hose nut (1) to refrigerant hose (2). Tighten nut to 19 N·m (14 lb ft).
47. Clip in the power steering fluid reservoir.
48. Install power steering fluid reservoir bolt and tighten to 9 N·m (7 lb in).
49. Remove the CH-807 closure plugs .
50. Connect the fuel filler pipe to the multiport fuel injection fuel rail.
51. Remove the CH-807 closure plugs .
52. Connect the fuel tank vent pipe to the evaporative emission vent valve.
53. Remove the heater outlet hose from the bulkhead. Refer to Heater Outlet Hose Replacement.
54. Connect the booster vacuum pipe (1) to the intake manifold.
55. Install the heater inlet hose to the bulkhead. Refer to Heater Inlet Hose Replacement.
56. Install the heater outlet hose to the bulkhead. Refer to Heater Outlet Hose Replacement.
57. Install the transmission range selector lever cable (2) to the cable bracket.
58. Connect the transmission range selector lever cable terminal (1) to the transmission manual shift lever pin.
59. Check the range selector cable adjustment. Refer to Range Selector Lever Cable Adjustment.
60. Clip in the radiator surge tank.
61. Fill the cooling system. Refer to Cooling System Draining and Filling.
62. Install the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
63. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement.
64. Install the air cleaner housing. Refer to Air Cleaner Assembly Replacement.
65. Connect the 2 wiring harness plugs (1, 2).
66. Install the 4 wiring harness (2).
67. Install the 3 ground nuts (1) and tighten to 9 N·m (7 lb in).
68. Clip in the 3 wiring harness plugs (3).
69. Connect the wiring harness plug to the front compartment fuse block.
70. Install the front compartment fuse block (2).
71. Install the 3 front compartment fuse block bolts (1) and tighten to 22 N·m (17 lb in).
72. Install the front compartment fuse block cover (1).
73. Install the windshield washer solvent container filler tube (1).
74. Install the battery tray. Refer to Battery Tray Replacement.
75. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging.
76. Check the oil level and fill NEW engine oil up if necessary.
77. Close the hood.
78. Install the lower intermediate steering shaft bolt. Refer to Intermediate Steering Shaft Replacement.