Spark

Engine Replacement - with EN-49802 and EN-50176

Special Tools

For equivalent regional tools, refer to Special Tools .

Note: The front wheels of the vehicle must be maintained in the straight ahead position and the steering column must be in the LOCK position before disconnecting the steering column or intermediate shaft. Failure to follow these procedures will cause incorrect alignment of some components during installation and result in damage to the SIR coil assembly.

1. Turn the ignition key to the LOCK position.

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

2. Open the bonnet.
3. Depressurise the fuel system. Refer to Fuel Pressure Relief .
4. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
5. Recover the air conditioning (A/C) refrigerant. Refer to Refrigerant Recovery and Recharging .



6. Remove the lower intermediate steering shaft bolt (1).



7. Disconnect TCM connectors (1) and engine wiring harness (2).



8. Disconnect intake air temperature sensor connector (1).



9. Remove the clamps (1, 2).
10. Twist and pull the hoses to remove throttle body assembly.



11. Remove the 4 air cleaner assembly bolts (1).
12. Remove the air cleaner assembly.



13. Disconnect the accelerator cable, if equipped.
14. Remove the battery. Refer to Battery Replacement .



15. Remove the engine control module (ECM) bracket to battery tray retaining bolts (2).



16. Pull the engine control module (ECM) electrical connector lever (1) and disconnect the engine control module (ECM) electrical connector (2).



17. Remove the retainers (1) from the battery tray with a suitable tool.



18. Remove the bolts (1) and nut (3).
19. Remove the battery tray (2)



20. Remove the under hood body electrical centre (BEC) cover.



21. Remove the positive cable to body electrical centre (BEC) retaining nut (1).
22. Pull back the positive cable (3) to separate the positive cable retainer (2) from body.



23. Raise the upper plate with suitable tool.



24. Remove the under hood BEC upper plate to lower plate retaining bolts (2).
25. Disconnect the wiring harness plug (1) from the front compartment fuse block.



26. Remove the ground bolt (1) and put the wiring harness (2) aside.
27. Disconnect the wheel speed sensor connector (3).
28. Move the wiring harness retainer (4) aside with suitable tool.



29. Disconnect the heater inlet hose (1) and outlet hose (2) from the heater pipe.

Note: Plug or cap the hoses and inlets when separating the cooling system components, this prevents dirt and other contaminants from entering the cooling system.

30. Plug or cap the cooling system hoses and inlets.



31. Disconnect the transmission range selector lever cable terminal from the transmission lever pin. For manual gearbox refer to Manual Gearbox Gear Lever and Selector Lever Cable Replacement .
32. Press the locking tabs inward in order to release the transmission range selector lever cable from the cable bracket.



33. Disconnect the pan module connector (1).



34. Disconnect the ambient air temperature sensor connector (2) if equipped.

Note: Plug or cap the hoses and inlets when separating the cooling system components, this prevents dirt and other contaminants from entering the cooling system.

35. Disconnect the coolant hose (1) from the CRFM.




Note: With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the vacuum brake booster power reserve.

36. Deplete the vacuum brake booster power reserve.
37. Disconnect the vacuum hose (2) from upper intake manifold.
38. Reposition and retain the vacuum hose (2) away from the powertrain.
39. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
40. Remove the front wheels. Refer to Tyre and Wheel Removal and Installation .
41. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .



42. Remove the clips (2).
43. Remove the front air guard (1).



44. Remove the cover (1, 2).



45. Remove the clip (2) and the water deflector (1).



46. Place a suitable container beneath the radiator and engine.

Note: Plug or cap the hoses and inlets when separating the cooling system components, this prevents dirt and other contaminants from entering the cooling system.

47. Drain the cooling system by disconnecting lower coolant hose as shown.




Note: DO not remove power steering fluid hose from power steering fluid reservoir.

48. Remove power steering fluid reservoir bolts (1) and unclip the power steering fluid reservoir and retain it on the engine.
49. Disconnect the coolant hoses (3, 4, 7) from the coolant surge tank.

Note: Plug or cap the hoses and inlets when separating the cooling system components, this prevents dirt and other contaminants from entering the cooling system.

50. Plug or cap the cooling system hoses and inlets.
51. Remove the coolant surge tank to body retaining bolts (2).
52. Remove the coolant surge tank.



53. Disconnect the fuel feed hose (3) from the fuel feed pipe (1).

Note: Plug or cap the fuel feed pipe (1) and fuel feed hose (3) ends to prevent fuel leaks and/or contamination.

54. Plug or cap the fuel feed pipe (1) and fuel feed hose (3) ends.
55. Disconnect the evaporative emission (EVAP) purge line (4) from the purge solenoid.

Note: When removal is complete plug hose openings with a clean lint free cloth to prevent foreign matter entry.

56. Plug or cap the (EVAP) purge line (4) and the purge solenoid ends.



57. Remove the suction/discharge line pad to A/C compressor retaining bolt (2).
58. Disconnect the A/C suction/discharge line pad from the A/C compressor.

Note: Plug or cap the A/C suction/discharge pipe ends and the compressor ports immediately to prevent contamination and absorption of moisture from the atmosphere.

59. Plug or cap the A/C suction/discharge pipe ends and the compressor ports.

Note: The A/C sealing O-rings are a single use component and will not reseal. Install NEW A/C sealing O-rings whenever the A/C suction/discharge line pad is removed from the A/C compressor.

60. Remove and discard the A/C suction/discharge pipe sealing O-rings.




Note: Plug or cap the A/C suction/discharge pipe ends and the compressor ports immediately to prevent contamination and absorption of moisture from the atmosphere.

61. Remove A/C compressor and condenser hose nut (1) from A/C condenser.




Note: DO NOT disconnect the hydraulic brake flexible hose from the brake calliper otherwise complete bleeding of the braking system will be necessary.

62. Detach the front brake hose (2) from the strut mounted brake hose retaining bracket and remove the front brake calliper anchor plate to knuckle retaining bolts (1). Repeat for opposite side.
63. Remove the front brake calliper from the front steering knuckle. Repeat for opposite side.




Caution: Support the brake calliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the calliper in this manner will cause the flexible brake hose to bear the weight of the calliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.

64. Support the front brake calliper (1) with heavy mechanic's wire, or equivalent (2). Repeat for opposite side.



65. Remove the wheel speed sensor retaining bolt (1) and detach wheel speed sensor harness (2) from the strut mounted retaining bracket.
66. Secure away from the cradle and suspension components. Repeat for opposite side.



67. Remove the bolts (3) and nuts (1, 4).
68. Remove the stabiliser shaft link (2) from the strut mounted retaining bracket. Repeat for opposite side.



69. Disconnect the oxygen sensor connector (1).
70. Remove the exhaust flexible pipe. Refer to Exhaust Pipe Replacement .



71. Install the EN-50176 powertrain support pallet, EN-49802 cradle support, and EN-50177 cradle support holder . Refer to Engine/Transmission Mounting : with CH-49289 and CH-49290 → with EN-49802 and EN-50176 .



72. Position the EN-48244 engine assembly remove/install pallet support or suitable powertrain and/or engine lift table below the frame as shown.
73. Lower the vehicle until the EN-49802 cradle support contacts the EN-48244 engine assembly remove/install pallet support or suitable powertrain and/or engine lift table.
74. Remove the 4 cradle bolts (1).



75. Remove the engine mount retaining bolt (3) and nuts (4).
76. Remove the transmission retaining bolt (1) and nut (2).




Note: Make sure that all the hoses, wires, pipes and front struts clear the vehicle during the removal process.

77. With the aid of an assistant, lower the table and/or raise the vehicle to remove the engine, transmission, and cradle assembly from the vehicle.



78. Remove the suction/charge line pad to A/C compressor retaining bolt and suction/charge line pad to condenser retaining nut.
79. Disconnect the A/C suction/charge line pad from the A/C compressor.

Note: Plug or cap the A/C suction/discharge pipe ends and the compressor ports immediately to prevent contamination and absorption of moisture from the atmosphere.

80. Plug or cap the A/C suction/charge pipe ends, condenser ports and the compressor ports.

Note: The A/C sealing O-rings are a single use component and will not reseal. Install NEW A/C sealing O-rings whenever the A/C suction/discharge line pad is removed from the A/C compressor.

81. Remove and discard the A/C suction/charge pipe sealing O-rings.
82. Discard the O-rings.
83. Remove the condenser radiator fan module (CRFM).



84. Disconnect the idle air control valve (IACV) connector (1), throttle position sensor (TPS) connector (2), manifold absolute pressure (MAP) sensor connector (3).



85. Disconnect the EGR connector (1), camshaft position sensor connector (2), thermostat heater connector (3), engine coolant temperature sensor connector (4) and DIS connector (5).



86. Disconnect the alternator harness connector (1), oil pressure switch connector (2) and knock sensor connector (7).
87. Remove the battery positive cable to alternator retaining nut.
88. Disconnect the battery positive cable (3) from the alternator.
89. Remove the battery cable harness to starter motor retaining nut.
90. Disconnect the battery cable harness (4, 5) from the starter motor.
91. Remove the engine wiring harness ground to cylinder block retaining bolt (6).



92. Disconnect the intake manifold runner control valve connector (1) and detach the wiring harness (5) from intake manifold.



93. Disconnect the canister purge solenoid connector (1) and the injector harness electrical connector (2).



94. Disconnect the power steering connector (1), and A/C compressor electrical connector (2).
95. Detach the engine wiring harness clip (3) from the bracket.
96. Remove the engine wiring harness from the powertrain.
97. Remove the power steering belt. Refer to Power Steering Pump Belt Removal .
98. Remove the drive belt. Refer to Drive Belt Removal .
99. Remove the power steering pump. Refer to Power Steering Pump Replacement .
100. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement .
101. Remove the alternator. Refer to Generator Replacement .
102. Loosen the transmission bolts and remove. Refer to Transmission Replacement for the Y4M transmission and Transmission Replacement for the Jatco transmission.
103. Attach a suitable lifting chain and hooks to lift bracket.
104. Using a suitable lifting crane, raise the engine.
105. Install the engine to the EN-49271 engine stand as needed.
106. Transfer parts as needed.

1. Attach a suitable lifting chain and hooks to lift bracket.
2. Using a suitable lifting crane, raise the engine.
3. Install the engine to the transmission and cradle.
4. Install the transmission bolts. Refer to Transmission Replacement for the Y4M transmission and Transmission Replacement for the Jatco transmission.
5. Install the alternator. Refer to Generator Replacement .
6. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement .
7. Install the power steering pump. Refer to Power Steering Pump Replacement .
8. Install the drive belt. Refer to Drive Belt Tensioner Installation .
9. Install the power steering belt. Refer to Power Steering Pump Belt Installation .



10. Install the engine wiring harness to the powertrain.
11. Attach the engine wiring harness clip to the bracket.
12. Connect the power steering connector (1), and A/C compressor electrical connector.



13. Connect the canister purge solenoid connector (1) and the injector harness electrical connector (2).



14. Connect the intake manifold runner control valve connector (1) and attach the wiring harness (5) to the intake manifold.



15. Connect the alternator harness connector (1), oil pressure switch connector (2), and knock sensor connector (7).
16. Install the battery cable harness (4, 5) to the starter motor.

Caution: Refer to Fastener Caution in the Preface section.

17. Tighten the battery cable harness (5) to starter motor retaining nut to 10 N·m (89 lb in).
18. Tighten the battery cable harness (4) to starter motor retaining nut to 5.5 N·m (49 lb in).
19. Install the engine wiring harness ground to cylinder block and tighten the bolt (6) to 50 N·m (37 lb ft).



20. Connect the EGR connector (1), camshaft position sensor connector (2), thermostat heater connector (3), engine coolant temperature sensor connector (4), and DIS connector (5).



21. Connect the idle air control valve (IACV) connector (1), throttle position sensor (TPS) connector (2), manifold absolute pressure (MAP) sensor connector (3).



22. Install the condenser radiator fan module (CRFM).



23. Install the new O-rings (3, 4).
24. Remove the plug or cap from the A/C suction/charge pipe ends, condenser ports and the compressor ports.
25. Connect the A/C suction/charge line (5) to the A/C compressor.
26. Tighten the suction/charge line pad to A/C compressor retaining bolt (1) to 22 N·m (16 lb ft).
27. Tighten the suction/charge line pad to condenser retaining nut (2) to 10 N·m (89 lb in).



28. With the aid of an assistant, raise the table and/or lower the vehicle to install the engine, transmission, and cradle assembly to the vehicle.



29. Install the transmission retaining bolt (1) and nut (2).
30. Install the engine mount retaining bolt (3) and nuts (4).
31. Tighten the transmission retaining bolt (1) and nut (2) to 75 N·m (55 lb ft).
32. Tighten the engine mount retaining bolt (3) and nuts (4) to 58 N·m (43 lb ft).



33. Tighten the 4 cradle bolts (1) to 170 N·m (125 lb ft).
34. Remove the EN-48244 engine assembly remove/install pallet support or suitable powertrain and/or engine lift table.



35. Remove the EN-50176 powertrain support pallet, EN-49802 cradle support, and EN-50177 cradle support holder . Refer to Engine/Transmission Mounting : with CH-49289 and CH-49290 → with EN-49802 and EN-50176 .
36. Install the exhaust flexible pipe. Refer to Exhaust Pipe Replacement .



37. Connect the oxygen sensor connector (1).



38. Install the stabiliser shaft link (2) to the strut mounted retaining bracket.
39. Install the bolts (3) and nuts (4).
40. Tighten the bolts (3) and nuts (4) to 100 N·m (74 lb ft).
41. Tighten the nut (1) to 43 N·m (32 lb ft).



42. Install the wheel speed sensor and attach wheel speed sensor harness (2) to the strut mounted retaining bracket and tighten the bolt (1) to 8.5 N·m (75 lb in).




Caution: Make sure the brake hose is not twisted or kinked after installation. Damage to the hose could result.

43. Remove the heavy mechanic's wire, or equivalent support (2) from the brake calliper (1).
44. Install the brake calliper assembly (1) to the steering knuckle (3).




Caution: Make sure the brake hose is not twisted or kinked after installation. Damage to the hose could result.

45. Tighten the brake calliper anchor plate to knuckle retaining bolts (1) to 95 N·m (70 lb ft).
46. Attach the brake hose (2) to the strut mounted brake hose retaining bracket. Repeat for opposite side.



47. Remove the plug or cap from A/C suction/discharge pipe ends and the compressor ports.

Note: DO NOT coat the new sealing washer with oil. They must be fitted dry. The use of mineral oil will render the washer useless, as the washer WILL swell causing refrigerant to leak out.

48. Install the new O-ring.
49. Install A/C compressor and condenser hose to A/C condenser and tighten the nut (1) to 10 N·m (89 lb in).



50. Remove the plug or cap from the A/C suction/discharge pipe ends and the compressor ports.

Note: The A/C sealing O-rings must be fitted dry. DO NOT lubricate the A/C sealing O-rings.

51. Fit the NEW A/C suction/discharge pipe sealing O-ring to the suction pipe.
52. Connect the A/C suction/discharge line pad to the A/C compressor.
53. Tighten the suction/discharge line pad to A/C compressor retaining bolt (2) to 22 N·m (16 lb ft).



54. Remove the plug or cap from the (EVAP) purge line (4) and the purge solenoid ends.
55. Connect the evaporative emission (EVAP) purge line (4) to the purge solenoid.
56. Remove the plug or cap from the fuel feed pipe (1) and fuel feed hose (3) ends.
57. Connect the fuel feed hose (3) to the fuel feed pipe (1).



58. Install the coolant surge tank (5) to the bracket mounted on the engine mount.
59. Tighten the coolant surge tank to body retaining bolts (2) to 9 N·m (80 lb in).
60. Remove the plug or cap from the cooling system hoses and inlets.
61. Connect the coolant hoses (3, 4, 7) to the coolant surge tank.
62. Install the power steering fluid reservoir to the coolant surge tank.
63. Tighten the power steering fluid reservoir bolts (1) to 9 N·m (80 lb in).



64. Connect the lower coolant hose as shown.



65. Install the water deflector (1) and the clip (2).



66. Install the cover (1, 2).



67. Install the front air guard (1) and clips (2).
68. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .
69. Install the front wheels. Refer to Tyre and Wheel Removal and Installation .
70. Lower the vehicle. Refer to Lifting and Jacking the Vehicle .



71. Connect the vacuum hose (2) to upper intake manifold.



72. Remove the plug or cap from the hoses and inlets.
73. Connect the coolant hose (1) to the CRFM.
74. Connect the ambient air temperature sensor connector (2) if equipped.



75. Connect the pan module connector (1).



76. Install the transmission range selector lever cable to the cable bracket.
77. Connect the transmission range selector lever cable terminal to the transmission lever pin. For manual gearbox refer to Manual Gearbox Gear Lever and Selector Lever Cable Replacement .
78. Check the range selector cable adjustment. Refer to Range Selector Lever Cable Adjustment .



79. Remove the plug or cap from the cooling system hoses and inlets.
80. Connect the heater inlet hose (1) and outlet hose (2) to the heater pipe.



81. Install the wiring harness retainer (4).
82. Connect the wheel speed sensor (3).
83. Install the ground wiring harness (2) and tighten the bolt (1) to 10 N·m (89 lb in).



84. Connect the wiring harness plug (1) to the front compartment fuse block.
85. Tighten the under hood BEC upper plate to lower plate retaining bolts (2) to 6 N·m (53 lb in).
86. Install the upper plate.



87. Install the positive cable to the positive cable retainer (2) to body.
88. Tighten the positive cable to body electrical centre (BEC) retaining nut (1) to 10 N·m (89 lb in).



89. Install the under hood body electrical centre (BEC) cover.



90. Install the battery tray (2) and tighten the bolts (1) and nut (3) to 11.5 N·m (102 lb in).



91. Install the retainers (1) to the battery tray.



92. Push the engine control module (ECM) electrical connector lever (1) while pushing engine control module (ECM) electrical connector (2) to engine control module (ECM).



93. Tighten the engine control module (ECM) bracket to battery tray retaining bolts (2) to 10 N·m (89 lb in).
94. Install the battery. Refer Battery Replacement .



95. Connect the accelerator cable, if equipped.



96. Install the air cleaner assembly and tighten the 4 air cleaner assembly bolts (1) to 6 N·m (53 lb in).



97. Install the hoses to throttle body assembly.
98. Tighten the clamp (2).



99. Connect intake air temperature sensor connector (1).



100. Connect the TCM connectors (1) and engine wiring harness (2).



101. Install the lower intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement .
102. Tighten the bolt (1) to 25 N·m (18 lb ft).
103. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
104. Refill the cooling system. Refer to Cooling System Draining and Filling .
105. Check the oil level and fill NEW engine oil up if necessary.
106. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
107. Close the bonnet.