Engine Assembly

Removal & Installation

2.4L Engine

To Remove:

1. Remove the side under cover.
2. Reduce the fuel line pressure.
3. Drain the engine oil.
4. Drain the engine coolant.
5. Drain the transmission oil.
6. Drain the transmission fluid.
7. Remove the hood.
8. Remove the Engine Control Module (ECM) (M/T) or Powertrain Control Module (PCM) (A/T).
9. Remove the air cleaner.
10. Remove the battery and the battery tray.
11. Remove the radiator assembly.
12. Remove the exhaust pipe.
13. Disconnect the control wiring harness.
14. Disconnect the evaporative emission purge hose.
15. Disconnect the brake booster vacuum hose.
16. To remove the drive belt, do the following:
    • Step 1: Insert the spindle handle or ratchet handle at a ½ in (12.7 mm) angle into the jig hole of the auto-tensioner.

      CAUTION
      If you plan to reuse the drive belt, use chalk to draw an arrow on the back of the belt to show the rotating direction.

    • Step 2: Turn the auto-tensioner counterclockwise and line up the 2 holes.
    • Step 3: Insert an L-shaped hexagon wrench, or its equivalent, into the hole to secure its position before removing the drive belt.
17. With the hose installed, remove the power steering oil pump and bracket assembly then use a cord to secure it to an area where it will not get in the way during the rest of the removal procedure.
18. With the hose installed, remove the A/C compressor and clutch assembly from the bracket then use a cord to secure it to an area where it will not get in the way during the rest of the removal procedure.
19. On an automatic transmission vehicle, with the hose installed, remove the ATF warmer (transmission fluid cooler) and bracket assembly from the transaxle case front roll stopper bracket.
20. Disconnect the heater water hoses.
21. Disconnect the high pressure fuel line. To disconnect the fuel high-pressure hose, remove the fuel high-pressure hose stopper. Next, pull upward on the retainer and remove the fuel high-pressure hose.

    CAUTION
    When removing the transaxle assembly on a manual transmission vehicle, do not remove the flywheel bolt because the flywheel assembly will then be out of balance and get damaged.

22. Remove the transaxle. To remove the transaxle assembly, secure the A/C condenser and front-end structure bar with a cord in an area where they won’t get in the way during the rest of the procedure.
23. Disconnect the grounding cable.
24. With the hose installed, remove the power steering oil reservoir then use a cord to secure it to an area where it will not get in the way during the rest of the removal procedure.
25. Remove the jam nuts.
26. Before removing the engine front mounting bracket, support the engine with a garage jack.
27. Remove the engine hanger tool (#MB991895 or #MB991928) then hold the engine assembly with a chain block.
28. Put a garage jack against the engine oil pan with a piece of wood in between to ensure that the engine assembly weight is not on the engine front mounting bracket.
29. Loosen the engine front mounting bracket nuts and bolts so you can remove the bracket itself.
30. Once you have made sure that all of the hoses, cables, wiring harness connectors, etc. are no longer connected to the engine, lift the chain block carefully to take the engine assembly out.

To Install:

1. Using an engine hanger (special tool #MB991527) and an engine hanger balancer (special tool #MB991454), install the engine assembly and be cautious so you do not pinch any hoses, cables, wiring harness connectors, etc.
2. When installing the engine front mounting bracket put a garage jack against the engine oil pan with a piece of wood in between, and install the engine front mounting bracket while you adjust the engine position.
3. Be sure to support the engine assembly with a garage jack, then remove the chain block.
4. Use an engine hanger (#MB991895 or #MB991928) to support the engine.
5. Install the jam nuts.
6. Install the power steering oil reservoir.
7. Install the grounding cable connection.
8. Install the transaxle assembly then remove the cord on the A/C condenser and the front-end structure bar.
9. Before connecting the fuel high-pressure hose, apply a small amount of clean engine oil to the fuel line pipe.

   CAUTION
   Once the fuel high-pressure hose is connected, slightly pull on it to ensure it is properly installed. Also check to make sure there is a play of about 0.12 in (3 mm). After that, install the stopper.

10. Connect the heater water hoses.
11. On vehicles with automatic transmission, connect the ATF warmer (transmission fluid cooler) and bracket assembly.
12. Install the A/C compressor and clutch assembly.
13. Install the power steering oil pump and bracket assembly.
14. Install the drive belt.
15. When connecting the brake booster vacuum hose, make sure to insert the hose with its paint mark facing up.
16. Connect the evaporative emission purge hose connection.
17. Connect the control wiring harness.
18. Install the exhaust pipe and main muffler.
19. Install the radiator.
20. Install the battery and tray.
21. Install the air cleaner.
22. Install the ECM or PCM.
23. Install the hood.
24. Refill the transmission oil.
25. Refill the transmission fluid.
26. Refill the engine coolant.
27. Refill the engine oil.
28. Check for fuel leaks.
29. Check the drive belt tension.
30. Install the side under cover.
31. Check the front wheel alignment and if necessary, make adjustments.

3.8L Engine

To Remove:

1. Remove the side under cover.
2. Remove the radiator grille.
3. Reduce the pressure in the fuel line.
4. Drain the engine coolant.
5. Drain the engine oil.
6. Remove the hood.
7. Remove the PCM.
8. Remove the air cleaner.
9. Remove the front exhaust pipe.
10. Remove the strut tower bar.
11. Remove the battery and tray.
12. Remove the engine cover.
13. Disconnect the control wiring harness.
14. Disconnect the vacuum hose.
15. Disconnect the evaporative emission purge hose.
16. Remove the fuel high-pressure hose stopper then remove the fuel high-pressure hose while the retainer is pulled up.
17. Disconnect the heater hose.
18. Remove the drive shaft.
19. Remove the right exhaust manifold. As you remove the exhaust manifold be sure not to remove the center exhaust pipe, and pull out the exhaust manifold (right bank) between the cylinder block and the crossmember.
20. Remove the radiator and secure the A/C condenser and front-end structure bar out of the way with a cord.
21. Remove the intake manifold plenum.
22. Remove the generator drive belt.
23. Remove the power steering oil pump drive belt.
24. Disconnect the power steering pressure switch.
25. Remove the power steering oil pump with the hose still attached. Secure the removed pump out of the way with cord.
26. Remove the starter assembly.
27. Remove the engine hanger and engine oil dipstick tube.
28. Remove the throttle body stay.
29. Remove the power steering pressure hose clamp bracket.
30. Remove the rear intake manifold plenum stay.

    NOTE: Once you remove the intake manifold plenum stay (rear), throttle body stay, engine oil dipstick assembly, and engine hanger, place the engine hanger plates (special tools #MB992012 and #MB992013) as shown.

31. Remove the transaxle assembly.

    Engine hanger plates (3.8L)

32. Remove the A/C compressor with the lines attached and secure it out of the way.
33. Remove the engine mounting stay.
34. Disconnect the grounding cable.
35. Remove the power steering oil reservoir.
36. Remove the engine front mounting bracket.
37. When removing the engine front mounting bracket, do the following:
    • Step 1: Support the engine with a jack.
    • Step 2: Remove the engine hanger (special tool #MB991895 or #MB991928).
    • Remove the engine hanger balancer (special tool #MB991454) and hook it again as seen in the illustration. Hold the engine assembly with the chain block, etc.

      Engine hanger balancer #MB991454

    • Put a jack against the engine oil pan with a piece of wood in between so the weight of the engine is not on the engine mount.
    •  Loosen the engine mounting nuts and bolts then remove the engine mount.
38. When removing the engine assembly, first make sure all hoses, cables, wiring harness connectors, etc. are disconnected from the engine. Lift the chain block carefully to slowly remove the engine assembly.

To Install:

1. When installing the engine assembly, make sure not to pinch the hoses, cables, or wiring harness connectors.

   Engine hanger balancer #MB991454

2. When installing the engine front mounting bracket, place a jack against the engine oil pan with a piece of wood in between, then install the engine mount while adjusting the position of the engine.
3. Carefully support the engine assembly with a jack, then remove the chain block.
4. If using special tool #MB991895, do the following:
   • Step 1: Place the engine hanger (special tool #MB991895) onto the strut mounting nuts toward the rear and the front-end structure bar assembling bolts toward the front.
   • Step 2: Remove the engine hanger balancer (special tool #MB991454).
   • Step 3: Hook it again, then set the engine hanger balancer to hold the engine assembly.
5. If using special tool #MB991928, do the following:
   • Step 1: Assemble the engine hanger (special tool #MB991928) and set the following parts onto the hanger:
     1. Slide bracket (HI)
     2. Standard foot (#MB991932)
     3. Joint (140) (#MB991931)
   • Step 2: Set the engine hanger to the strut mounting nuts toward the rear and the front-end structure bar assembling bolts toward the front.
   • Step 3: Remove the engine hanger balancer (#MB991454) then hook it again.
   • Step 4: Set the engine hanger balancer to hold the engine assembly.

   NOTE: The engine hanger balance can be adjusted by sliding the slide bracket.

6. Install the engine mount bracket.
7. Install the power steering oil reservoir.
8. Connect the grounding cable.
9. Install the engine mounting stay.
10. Install the A/C compressor assembly.
11. Connect the A/C compressor assembly connector.
12. Install the transaxle assembly.
13. Install the intake manifold plenum stay (rear).
14. Install the power steering pressure hose clamp bracket.
15. Install the throttle body stay.
16. Install the O-ring.
17. Install the engine oil dipstick assembly.
18. Install the engine hanger.
19. Install the starter assembly.
20. Install the starter connector and terminal.
21. Install the power steering oil pump.
22. Connect the power steering pressure switch.
23. Install the power steering oil pump drive belt.
24. Install the generator drive belt.
25. Install the intake manifold plenum.
26. Install the radiator.
27. Install the exhaust manifold (right bank).
28. Install the drive shaft.
29. Connect the heater hose.
30. Before connecting the fuel high-pressure hose, apply a bit of clean engine oil to the fuel line pipe.

    CAUTION
    Once you have connected the fuel high-pressure hose, lightly pull it to make sure that it is installed correctly. Be certain there is a play approximately 0.12 in (3 mm). Then install the stopper properly.

31. Install the evaporative emission purge hose connection.
32. Connect the vacuum hose.
33. Connect the control wiring harness.
34. Install the engine cover.
35. Install the right bank exhaust manifold.
36. Install the battery, tray, and bracket.
37. Install the strut tower bar.
38. Install the front exhaust pipe installation.
39. Install the air cleaner.
40. Install the ECM (M/T) or PCM (A/T).
41. Install the hood.
42. Check the drive belt tension.
43. Refill the engine oil.
44. Refill the engine coolant.
45. Check the system for any fuel leaks.
46. Install the under cover.