Engine - Removal

ENGINE ASSEMBLY










1. Perform the fuel pressure release procedure Service and Repair.
2. Disconnect and isolate the negative battery cable.
3. Recover the A/C system refrigerant Refrigerant System Recovery.
4. Remove the throttle body air inlet hose and air cleaner body assembly Air Cleaner Body - Removal.





5. Disconnect engine harness to main harness connectors (5) and (6).
6. Disconnect engine harness connector C2 (4) and transmission harness connector C4 (3) from the PCM.
7. Remove the nut (2) and black ground cable from the remote negative battery post.
8. Remove the nut (1) and the red starter cable from the remote positive battery post.





9. Remove the upper intake manifold (1) Intake Manifold - Installation.





10. Disconnect the fuel supply hose (2) from the fuel rail (1) Service and Repair.





11. Disconnect the gearshift cable (1) from the manual valve lever (2).










12. Disconnect the front downstream oxygen sensor (3) from the engine wiring harness connector (2).
13. Disconnect the front upstream oxygen sensor (5) from the engine wiring harness connector (1).





14. Disconnect the fan motor electrical connectors (4).
15. Disengage three wire harness retainers (3) and the wire harness connector (5) from the cooling fan module (2).
16. Remove five screws (1) retaining the wire harness to the upper core support.
17. Disengage the two upper retainers and remove the cooling fan module (2) from the radiator.





18. Remove the generator B+ terminal and field connection.





19. Remove the bolt (1) and the engine oil dipstick and tube (2).





20. Disconnect the engine wire harness (1) from the A/C compressor connector (2).
21. Remove the nut (4) that secures the A/C suction line (6) to the A/C compressor (3).
22. Disconnect the A/C suction line from the A/C compressor and remove and discard the O-ring seals and gaskets.
23. Install plugs in, or tape over the A/C suction line and A/C compressor fittings.





24. Disconnect the wire harness connector (1) from the A/C pressure transducer (6) located near the right side of the radiator (5).
25. Remove the nut (3) that secures the A/C discharge line to the discharge jumper line (4).
26. Disconnect the A/C discharge line from the jumper line and remove and discard the O-ring seal and gasket.
27. Install plugs in, or tape over the discharge and jumper line fittings.





28. Raise and support the vehicle on a hoist Maintenance
29. Remove the belly pan (2), if equipped.
30. Drain the engine oil Service and Repair.





31. Remove the front tire and wheel assemblies Tires and Wheels - Removal





32. Remove the left and right lower frame splash shields (2).





33. Remove the closeout panel (1) from the fascia (3) Front Lower Fascia Closeout - Removal.
34. Drain the cooling system Service and Repair.





35. Remove both axle shafts (2) Half Shaft - Removal.





36. Remove left and right splash shields (2) Splash Shield - Removal.





37. Remove the fore/aft cross-member (4) Crossmember - Removal










38. Remove the accessory drive belt (2) Serpentine Accessory Drive Belt - Removal.










39. Remove the power steering belt (2) Serpentine Accessory Drive Belt - Removal.





40. Remove the power steering pump mounting bracket bolt (1) near the pump pulley.





41. Do not disconnect the power steering lines from the pump. Remove the two power steering pump mounting bracket bolts (2) behind the pump on the back of the engine and reposition the power steering pump and bracket assembly (1).





42. Remove the crossunder pipe (3) Exhaust Cross under Pipe to Resonator - Removal





43. Disconnect the heater return hose (1) from the pipe connection at right front frame rail area.
44. Remove the lower radiator hose (2).





45. Support the A/C compressor (1) and remove the three bolts (2) that secure the compressor to the engine and remove the compressor with the discharge line attached.





46. Remove the three generator mounting bolts and remove the generator.





47. Lower the vehicle.
48. Remove the upper radiator hose (5) from the coolant outlet connector (4).
49. Remove the heater hose (3) from the coolant outlet connector (4).
50. Remove the mounting screw (1) and reposition the power steering reservoir (2).





51. Disconnect the return hose (2) from the coolant recovery container (4).
52. Remove two fasteners (1) and lift the coolant recovery container (4).
53. Disconnect the coolant recovery container hose (3) and remove the coolant recovery container (4).





54. Remove the front upper maniverter heat shield fasteners (1) and remove the heat shield (2).





55. Remove the front exhaust maniverter attaching bolts (1), front maniverter (2) and gasket (3).





56. Remove the lower EGR tube (2) Exhaust Gas Recirculation (EGR) Tube - Removal.





57. Raise and support the vehicle.
58. Remove the heat shield bolts (2) and the heat shield (3).
59. Remove the intermediate shaft bolts (1) and (5) and remove the intermediate shaft (4).










60. Disconnect the rear downstream oxygen sensor (3) from the engine wiring harness connector (5).
61. Disconnect the rear upstream oxygen sensor (2) from the engine wiring harness connector (1).





62. Remove the fasteners (1 and 2) and the rear maniverter heat shield (3).





63. Remove the rear maniverter fasteners (1), rear maniverter (2) and rear maniverter gasket (3).





64. If equipped with the 62TE transmission, remove the bolt (1) and torque converter dust shield (2).





65. If equipped with the 41TE transmission, remove the bolts (1) and (2) and the structural collar (3).





66. Mark the driveplate to torque converter position. Remove the driveplate bolts (1).





67. Remove the transaxle bracket to isolator through bolt (1).
68. Remove the transaxle bracket bolt (3).





69. Lower the vehicle.
70. Disconnect the oil cooler lines from the transaxle. Plug the lines and fittings to prevent debris from entering the transaxle or cooler circuit.
71. Remove the remaining three transaxle bracket bolts (1) and remove the transaxle bracket.





72. Adjust the vehicle height to allow the Powertrain Dolly 6135 (2) and Engine Support Cradle 6710A (3) with Cradle Posts 6848 and Cradle Post Adapter 6848 to be installed under the vehicle.





73. Place the Cradle Post Adapter 6848 (2) between the A/C compressor mounting bracket (1) and the cradle post (3).
74. Loosen the cradle post mounts to allow movement for positioning to the A/C compressor mounting bracket, the front engine mounting bracket and the oil pan rail. Lower the vehicle and position the cradle until the engine is resting on the posts. Tighten the post mounts to the cradle frame to prevent movement when removing or installing engine/transaxle assembly.





75. Continue lowering the vehicle so that the weight of the engine and transmission ONLY is on the cradle.
76. Remove the three right side engine mount bolts (1).





77. Remove the two left side transaxle mount bolts (2).





78. Secure the engine/transaxle assembly to the dolly/cradle with a safety strap (1). Slowly raise the vehicle in short length spans. Inspect at each interval for potential engine or transaxle contact to vehicle components. Move the cradle/dolly fixture as necessary to allow for removal clearance.