Engine Removal and Replacement CHAPTER 11 Engine Removal and Replacement

Introduction If well-maintained, engine can last 200,000 miles (322,000 kilometers [km]). Engine will let you know if something is wrong. Noise Crank Dash lights (MIL)

Engine Removal Tools (1 of 3) Service tools Vehicle lift Engine hoist

Engine Removal Tools (2 of 3) Engine stand Jacks Hand tools

Engine Removal Tools (3 of 3) Scan tool Chain Scissor jack

Preparation and Safety (1 of 3) Similar engine removal: Front-wheel drive Rear-wheel drive All-wheel drive

Preparation and Safety (2 of 3) Rear-wheel drive is best removed from top. Engine separated from transmission and removed by itself Engine and transmission removed as unit

Preparation and Safety (3 of 3) Front-wheel drive is removed from top or bottom. If from bottom, engine and transaxle removed as unit attached to engine cradle Respect and implement shop safety standards and regulations.

Topside Disconnection (1 of 5) Remove hood. Mark hood bracket where bolts attach. Disconnect everything within reach.

Topside Disconnection (2 of 5) Most vehicles are fuel injected. Relieve pressure on fuel system before removing lines.

Topside Disconnection (3 of 5) Fuel injection disconnect tool Ten or more computers control systems.

Topside Disconnection (4 of 5) Disconnect battery first. Prevent damage.

Topside Disconnection (5 of 5) Be methodical when disconnecting electrical wires and connectors.

Front Accessories Disconnection (1 of 4) Next step, remove radiator and accessories. Let engine cool off. Drain.

Front Accessories Disconnection (2 of 4) Removing the electric fans. Removing the radiator.

Front Accessories Disconnection (3 of 4) Air-conditioning compressors and power steering pumps are mounted to engine with brackets.

Front Accessories Disconnection (4 of 4) Exhaust assembly with oxygen sensors. Removing the exhaust pipe from the vehicle.

Underside Disconnection (1 of 5) Take your time, work carefully and methodically, and review manufacturer’s information prior to disconnection. Drain engine oil, transmission/transaxle fluid, and the cooling system.

Underside Disconnection (2 of 5) Today’s exhaust systems: Three or four oxygen sensors Catalytic converter Turbocharger Particulate filters

Underside Disconnection (3 of 5) Removing the starter wires. Removing the starter bolts.

Underside Disconnection (4 of 5) The engine of a front-wheel drive vehicle strapped to a scissor jack. Unbolt the motor mounts.

Underside Disconnection (5 of 5) Remove the cradle bolts. Lower the scissor jack.

Engine Removal (1 of 2) Always have two other people assist you. One person operates hoist; two others guide engine. Do final check. Anything that might have been disconnected Use chain to connect engine to lifting points.

Engine Removal (2 of 2) Using at least grade 5 bolts, bolt engine to stand.

Engine Installation (1 of 4) Have assistants just as with engine removal. Reverse removal process to install engine, with a few additional steps.

Engine Installation (2 of 4) Automatic transmissions, change front transmission seal. Fill torque converter with proper transmission fluid.

Engine Installation (3 of 4) Manual transmissions, clutch discs align with clutch pilot hole. Align clutch disc and install pressure plate. Turn splined input shaft to align with clutch disc splines.

Engine Installation (4 of 4) After transmission is bolted to engine, mount engine to vehicle frame. Attach. Lower. Tighten.

Engine Start-up (1 of 6) Fluid levels correct and no leaks Battery connected and charged Fuel supplied to injection system

Engine Start-up (2 of 6) If ignition timing adjustable, set to adjust when engine starts.

Engine Start-up (3 of 6) Auxiliary components properly installed Serpentine belt and pulleys properly installed Electrical connectors and vacuum hoses properly connected

Engine Start-up (4 of 6) Connect exhaust removal hose to exhaust pipe.

Engine Start-up (5 of 6) Brake pedal not spongy Crank engine for 10 seconds or less. Run 20 to 30 minutes for proper lubrication. Ensure piston rings are seated properly and camshaft and other components are not damaged.

Engine Start-up (6 of 6) After engine is started, connect a DLC and check for DTCs. Check for leaks, fluid levels, missing components. Drive 30 minutes without exceeding 50 mph.

Summary (1 of 10) Before the engine fails, there are usually warning signs such as dash warning lights indicating low oil pressure, high operating temperature, or a malfunctioning emission control system. The first step in performing an engine removal installation task is to reference the appropriate service information, preferably the manufacturer’s service information.

Summary (2 of 10) The tools needed to remove and replace an engine include special service tools, a vehicle lift, an engine hoist, jacks, and general shop hand tools. Make sure the engine hoist is rated for the weight capacity you will be lifting. Once the engine has been removed from the vehicle, use an engine stand to support the engine while taking it apart.

Summary (3 of 10) There are many engine installation configurations. They include front-wheel drive, rear-wheel drive, and all-wheel drive designs. Engine removal and installation can be dangerous; therefore, it is important to put safety first in each step of the process.

Summary (4 of 10) Modern vehicles typically have 10 or more computers monitoring and controlling virtually every operational system of the vehicle. Disconnect the battery before disconnecting any other component from the engine. When disconnecting the battery, remove the negative terminal from the battery first.

Summary (5 of 10) Typically, a fuel injection supply line stays under pressure even when the engine is not running. Therefore, you will need to relieve the pressure on the fuel system before disconnecting the fuel line. If an air-conditioning system needs to be opened, the refrigerant will need to be removed and stored using the appropriate recycling machine.

Summary (6 of 10) The boiling point of engine coolant is increased by the coolant properties, and the cooling system pressure is maintained by the pressure cap. Make sure the engine is cool before draining the radiator. Air-conditioning compressors and power steering pumps are examples of accessory components that are mounted to the engine.

Summary (7 of 10) Currently produced vehicles could have three or four oxygen sensors, a catalytic converter, and a turbocharger driven by the exhaust. The starter motor is normally located where the engine and the transmission are mounted together. When removing an engine, it is always helpful to have two other people assisting you.

Summary (8 of 10) Time spent organizing the work site will ensure a safe and smooth engine installation. When reinstalling the torque converter, push in and turn the torque converter, making sure three distinct clunks are felt.

Summary (9 of 10) Engine start-up after installation is a critical time for engine operation and longevity. To ensure that the piston rings are seated properly and that the camshaft and other internal components are not damaged, it is important to follow appropriate break-in procedures.

Summary (10 of 10) An important task after you have started the engine is to connect a diagnostic scanner to the data link connector (DLC) and check for diagnostic trouble codes (DTCs).

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