Removal Procedure

Engine Replacement


Special Tools
* J 24319-B Steering Linkage and Tie Rod Puller
* J 45341 Rear Wheel Drive Shaft Removal Tool
* J-2619-A Slide Hammer
* J 44394 Axle Seal Protector
* J 45059 Angle Meter



Removal Procedure





1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair) .
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair) .
3. Remove the charge air cooler inlet and outlet pipes. Refer to Charge Air Cooler Inlet Pipe Replacement (Charge Air Cooler Inlet Pipe Replacement) and Charge Air Cooler Outlet Pipe Replacement (Charge Air Cooler Outlet Pipe Replacement) .
4. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) (Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (With CH 48027) (Fuel Pressure Relief (With CH 48027)) .
5. Disconnect the evaporative emission (EVAP) canister purge solenoid tube from the valve (2). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service) .
6. Disconnect the fuel feed pipe (1) from the fuel line. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service) .




7. Remove the turbocharger heat shield bolts (1) and shield.




8. Remove the charge air cooler pipe to turbocharger bolts (1).
9. Remove the charge air cooler pipe and gasket (2) from the turbocharger.
10. Cap or plug the turbocharger opening.




11. Reposition the radiator inlet hose clamp (1) at the engine.
12. Remove the radiator inlet hose (2) from the engine.
13. Reposition the radiator inlet hose out of the way.




14. Reposition the radiator outlet hose clamp (2) at the thermostat housing.
15. Reposition the radiator outlet hose clamp (1) at the oil cooler.
16. Remove the radiator outlet hose from the thermostat housing and oil cooler.
17. Remove the radiator outlet hose clip (3) from the bracket.
18. Reposition the radiator outlet hose out of the way.




19. Reposition the heater inlet and outlet hose clamps at the thermostat housing.
20. Remove the heater inlet (1) and outlet (2) hoses from the thermostat housing.
21. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair) .
22. Drain the engine oil.
23. Unbolt the catalytic converter from the exhaust pipe.




24. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor.
25. Disconnect the engine wiring harness electrical connector (2) from the oil pressure sensor.




26. Disconnect the engine wiring harness electrical connector (1) from the brake booster vacuum pump.
27. Lower the vehicle.




28. Disconnect the engine wiring harness electrical connector (1) from the mass air flow (MAF) sensor.




29. Cut the engine harness tie straps (1).
30. Remove the negative battery cable ground bolt (6) from the front engine lift bracket.
31. Remove the negative battery cable ground terminal (5) from the engine lift bracket.
32. Reposition the negative/positive battery cable out of the way.




33. Disconnect the engine wiring harness electrical connector (1) from the transmission oil cooler pump.




34. Disconnect the engine wiring harness electrical connector (1) from the generator.




35. Reposition the positive battery cable terminal boot (2).
36. Remove the generator terminal nut (1).
37. Remove the positive battery cable terminal (3) from the generator.
38. Disconnect the engine wiring harness electrical connector (4) from the A/C compressor.




39. Disconnect the engine wiring harness electrical connector (1) from the fuel injector jumper electrical connector.




40. Disconnect the engine wiring harness electrical connector (2) from the knock sensor.




41. Disconnect the engine wiring harness electrical connector (1) from the A/C refrigerant pressure sensor.
42. Disconnect the charge air cooler electrical connector (2).




43. Disconnect the engine wiring harness electrical connector (2) from the intake camshaft position (CMP) sensor.
44. Disconnect the engine wiring harness electrical connector (1) from the high pressure fuel pump.
45. Remove the engine wiring harness clip (3) from the high pressure fuel pump bracket.




46. Disconnect the engine wiring harness electrical connector (2) from the intake CMP actuator.
47. Disconnect the engine wiring harness electrical connector (1) from the exhaust CMP actuator.
48. Disconnect the ignition coil electrical connectors (3) from the ignition coils.




49. Remove the engine harness clip (1) from the camshaft cover.




50. Disconnect the engine wiring harness electrical connector (1) from the heated oxygen sensor (HO2S) (3).




51. Disconnect the engine wiring harness electrical connector (4) from the exhaust CMP sensor.
52. Remove the engine harness ground terminal bolt (2) and reposition the engine harness ground terminal (1).
53. Disconnect the engine wiring harness electrical connector (3) from the engine coolant temperature (ECT) sensor.




54. Disconnect the engine harness clips (2) from the camshaft cover.
55. Disconnect the engine harness clip (1) from the camshaft cover.




56. Remove the engine wiring harness clip (3) from the turbocharger coolant feed pipe stud (2).
57. Remove the engine wiring harness clip (1) from the turbocharger coolant feed pipe tab.




58. Disconnect the engine wiring harness electrical connector from the boost sensor.




59. Remove the engine wiring harness ground bolt (2) from the cylinder head.
60. Remove the engine wiring harness ground terminal (1) from the cylinder head.




61. Remove the engine harness clips (3, 4) from the front studs.
62. Gather all branches of the engine harness and lay off to the side.
63. Reposition the charge air bypass valve vacuum hose clamp at the turbocharger.
64. Remove the vacuum hose from the turbocharger coolant feed pipe clips.
65. Remove the charge air bypass valve solenoid.




66. Remove the turbocharger coolant feed pipe bolt (1) at the turbocharger.
67. Remove the turbocharger coolant feed pipe fitting (2) from the cylinder head.
68. Remove the turbocharger coolant feed pipe bracket bolt from the cylinder head.
69. Remove the turbocharger coolant feed pipe bracket from the vehicle.




70. Remove the A/C compressor line bolt and reposition the line off to the side.
71. Raise and support the vehicle.




72. If equipped with a automatic transaxle, disconnect the engine harness from the transaxle.




73. If equipped with a automatic transaxle perform the following steps. Disconnect the engine coolant temperature (ECT) sensor electrical connector (1).
74. Remove the connector position assurance (CPA) retainer (2).
75. Disconnect the engine harness electrical connector (3) from the heater oxygen sensor (HO2S).




76. If equipped with a manual transaxle perform the following steps. Disconnect the ECT sensor electrical connector (1).
77. Remove the CPA retainer (2).
78. Disconnect the engine harness electrical connector (3) from the HO2S.




79. If equipped with a automatic transaxle perform the following steps. Remove the CPA retainer (5).
80. Disconnect the engine harness electrical connector (6) from the park neutral position switch.
81. Remove the engine harness clip (1) from the transaxle stud.
82. Remove the CPA retainer (2).
83. Remove the engine harness electrical connector clip (4) from the transaxle rear mount bracket.
84. Disconnect the engine harness electrical connector (3) from the HO2S.




85. If equipped with a manual transaxle, disconnect the engine harness electrical connector (1) from the VSS.
86. Remove the engine harness clip (2) from the transaxle.
87. Remove the CPA retainer (3).
88. Remove the engine harness electrical connector clip (5) from the transaxle rear mount bracket.
89. Disconnect the engine harness electrical connector (4) from the HO2S.
90. Disconnect the engine harness electrical connector (7) from the back up lamp switch.
91. Remove the engine harness clip (6) from the transaxle.
92. Gather all engine harness branches are reposition the harness off to the side, out of the way.




93. If equipped with a automatic transaxle, disconnect the range selector lever cable from the transaxle lever.
94. Remove the range selector lever cable from the transaxle bracket.




95. If equipped with a manual transaxle, disconnect the range selector and shift lever cables from the transaxle levers.
96. Remove the range selector and shift lever cables from the transaxle bracket.




97. If equipped with a automatic transaxle, remove the oil cooler line nut.
98. Remove the oil cooler lines from the transaxle.




99. Remove the left and right stabilizer link to strut nuts.
100. Separate the stabilizer links from the struts.




101. Remove the left and right steering gear outer tie rod to knuckle nuts. Discard the nuts.
102. Using the J 24319-B , separate the outer tie rods from the steering knuckles.




103. Remove the left and right ball joint to steering knuckle bolts and nuts.
104. Separate the lower ball joints from the steering knuckles.




105. Assemble the J 45341 and the J-2619-A .
106. Using the J 45341 and the J-2619-A , separate the right wheel drive shaft from the transaxle. Repeat for the left side.
107. Secure the wheel drive shafts out of the way.




108. Remove the lower radiator support bolts.
109. Secure the radiator assembly to the radiator core support with bungee cords.




110. Lower the vehicle to about 3 feet off the ground.
111. Position a engine lift table under the frame.
112. Place wood blocks on top of the lift table between the table and the frame.
113. Lower the vehicle until the frame is resting on the blocks of wood.
114. Remove the engine mount bracket bolts.




115. Remove the transaxle mount to transaxle bolts.




116. Remove the frame bolts using the following sequence:

1. Remove the front frame bolts.
2. Remove the rear frame bolts.

117. Slowly raise the vehicle up away from the powertrain assembly.
118. Slide the lift table out from under the vehicle.
119. Attach an engine lift hoist to the engine lift hooks.




120. If equipped with a automatic transaxle, remove the torque converter housing access plug.




121. If equipped with a automatic transaxle, remove the torque converter bolts.




122. If equipped with a automatic transaxle, remove the transaxle brace bolts and brace.




123. If equipped with a manual transaxle, remove the transaxle to engine bolts/stud.




124. If equipped with a automatic transaxle, remove the transaxle to engine bolts/stud.
125. Separate the engine from the transaxle.
126. If equipped with a manual transaxle, remove the clutch pressure plate and disc. Refer to Clutch Pressure and Driven Plate Replacement (Service and Repair) .
127. Remove the following components:

* The engine mount bracket
* The engine block heater, if equipped
* The generator

128. Using the engine hoist, install the engine to a suitable engine stand.