For 1990-2009 cars

#### Special Tools

• | EN-48613 Engine Assembly Remove/Install Pallet

• | EN-48244 Engine Assembly Remove/Install Pallet Supporter

### Removal Procedure

1. Discharge the air conditioning (A/C) system, if equipped.
2. Drain the power steering oil, if equipped.

Warning: Refer to Battery Disconnect Warning in the Preface section.

3. Disconnect the negative battery cable.
4. Remove the engine cover. Refer to Engine Cover Replacement.
5. Remove the charge air system hoses and ducts. Refer to Charge Air Cooler Inlet Pipe and Outlet Pipe Replacement.
6. Drain the engine coolant. Refer to Cooling System Draining and Filling.
7. Disconnect the fuel hose from the high pressure pump.
8. Remove the power steering pipe and hose.
9. Disconnect the fuel return hose from the junction block.
10. Remove the pipe and hose retaining bracket from the cylinder head cover.
11. Disconnect the coolant by-pass hose from the intake manifold.
12. Disconnect the radiator upper hose from the intake manifold.
13. Disconnect the radiator lower hose from the engine block.
14. Remove the engine wiring harness.

• | Disconnect the injector connectors.

• | Disconnect the engine oil pressure switch connector.

• | Disconnect the high pressure pump connector.

• | Disconnect the alternator connector.

• | Disconnect the coolant temperature sensor (CTS) connector.

• | Disconnect the common rail pressure sensor connector.

• | Disconnect the electronic throttle control (ETC) connector.

• | Disconnect the EGR vacuum solenoid connector.

• | Disconnect the A/C compressor connector.

• | Disconnect the camshaft position sensor (CMP) connector.

• | Disconnect the turbocharger actuator connector.

• | Disconnect the glow plug wire connector.

• | Disconnect the booster pressure (T-MAP) sensor connector.

• | Disconnect the common rail regulator connector.

• | Disconnect the starter solenoid wiring connector.

• | Disconnect the crankshaft position sensor.

• | Remove the glow plug fuse box.

• | Remove the generator B+ connector nut.

• | Remove the starter solenoid connector nut.

• | Remove the engine ground bolt.

• | Remove the transaxle ground bolt.

15. Remove the surge tank. Refer to Radiator Surge Tank Replacement.
16. Remove the right/left drive axle shaft.
17. Remove the transaxle wiring harness.
18. Remove the shift control cable from the automatic transaxle.
19. Remove the select cable from the transaxle.
20. Remove the transaxle oil cooler hoses from the automatic transaxle.
21. Remove the clutch actuator cylinder pipe from the transaxle.
22. Remove the centermember.
23. Remove the front exhaust pipe between the pre-catalyst and the DPF pipe. Refer to Front Pipe Replacement.
24. Remove the heater hoses.
25. Remove the A/C compressor pipe from the compressor.

Important: Only lower the vehicle far enough to take the weight off the engine and transaxle mount, or damage to the mount and pallet/pallet support failure may occur.

26. Lower the vehicle and position the engine assembly onto the engine assembly. Remove/install pallet EN-48613 with the EN-48244 .
27. Remove the engine mount.
28. Remove the transaxle mount bolt from the transaxle.
29. Remove the engine and transaxle.

### Installation Procedure

Caution: Refer to Fastener Caution in the Preface section.

1. Install the transaxle to the engine assembly.

Tighten

• | Tighten the transaxle tightening bolts to 75 N·m (55.3 lb ft).

• | Tighten the oil pan flange-to-transaxle bolts to 50 N·m (36.9 lb ft).

2. Install engine assembly to the vehicle by using the remove/install pallet EN-48613 with the EN-48244 .
3. Install the transaxle mount bolts.

Tighten
Tighten the transaxle mount bracket retaining bolts (1) to 40 N·m (30 lb ft).

4. Install the engine mount bolt.

Tighten
Tighten the engine mount bracket retaining bolt to 65 N·m (47.9 lb ft).

5. Remove EN-48613 with the EN-48244 from the vehicle.
6. Install the engine wiring harness.

• | Connect the injector connectors.

• | Connect the engine oil pressure switch connector.

• | Connect the high pressure pump connector.

• | Connect the alternator connector.

• | Connect the coolant temperature sensor (CTS) connector.

• | Connect the common rail pressure sensor connector.

• | Connect the electronic throttle control (ETC) connector.

• | Connect the EGR vacuum solenoid connector.

• | Connect the A/C compressor connector.

• | Connect the camshaft position sensor (CMP) connector.

• | Connect the turbocharger actuator connector.

• | Connect the glow plug wire connector.

• | Connect the booster pressure (T-MAP) sensor connector.

• | Connect the common rail regulator connector.

• | Connect the starter solenoid wiring connector.

• | Connect the crankshaft position sensor.

• | Install the glow plug fuse box.

Tighten
Tighten the glow plug fuse box bolts to 10 N·m (88.5 lb in).

• | Install the generator B+ connector nut.

Tighten
Tighten the generator B+ connector nut to 25 N·m (18.4 lb ft).

• | Install the starter solenoid connector nut.

Tighten
Tighten the starter solenoid connector nut to 15 N·m (11.1 lb ft).

• | Install the engine ground bolt.

Tighten
Tighten the engine block ground bolt to 25 N·m (18.4 lb ft).

• | Install the transaxle ground bolt.

Tighten
Tighten the transaxle ground bolt to 25 N·m (18.4 lb ft).