Engine - Removal
REMOVAL
Special Tools:
1. Perform the fuel pressure release procedure Service and Repair.
2. Disconnect and isolate the negative battery cable.
3. Raise and support the vehicle Maintenance.
4. Remove the belly pan.
5. Drain the cooling system Service and Repair.
6. Drain the engine oil Service and Repair.
7. Lower the vehicle.
8. Remove the engine cover (1).
9. Recover the refrigerant from the refrigerant system Refrigerant System Recovery.
10. Remove the air cleaner body (1) Air Cleaner Body - Removal.
11. Remove the resonator (1) Removal.
12. Remove the electric vacuum pump and mounting bracket (1) Removal.
13. Disconnect the fuel line (1) from the fuel rail inlet Service and Repair.
14. Remove the coolant recovery bottle (1) Coolant Recovery Bottle - Removal.
15. Disconnect the heater core return hose (1).
Remove the nut (2), bolt (3) and the heater core return tube (1).
16. Remove the upper intake manifold (2) Intake Manifold - Removal.
17. Remove the upper radiator hose (1).
18. Remove the cooling fan module (3) Cooling Fan - Removal.
19. Disconnect the heater core supply hose (1) Service and Repair.
20. Remove the accessory drive belt (7) Serpentine Accessory Drive Belt - Removal.
21. Remove the generator (2) Generator - Removal.
NOTE: Mark the variable valve timing solenoid connectors (2) with a paint pen or equivalent so that they may be reinstalled in their original locations.
22. Disconnect the electrical connectors (2) from the variable valve timing solenoids on the left cylinder head cover.
23. Disengage three wire harness retainers (1) from the left cylinder head cover.
24. Disconnect the left upstream oxygen sensor connector (1) from the main wire harness.
25. Disengage two upper wire harness retainers (2) from the intake manifold support brackets.
26. Disengage two lower wire harness retainers (3) from the intake manifold support brackets.
27. Disconnect the Engine Coolant Temperature (ECT) sensor connector (3).
28. Disconnect the left Camshaft Position (CMP) sensor (5).
29. Disengage one main wire harness retainer (2) from the cylinder head cover and one main wire harness retainer (4) from the cylinder head cover mounting stud.
30. Disengage the main wire harness retainer (1) form the rear of the lower intake manifold.
31. Disconnect the main harness from the engine injection/ignition harness (1) at the rear of the left cylinder head.
32. Disconnect the main harness from the engine oil pressure/temperature harness (2) at the rear of the left cylinder head.
NOTE: Mark the variable valve timing solenoid connectors (2) with a paint pen or equivalent so that they may be reinstalled in their original locations.
33. Disconnect the electrical connectors (2) from the variable valve timing solenoids on the right cylinder head.
34. Disengage two wire harness retainers (1) from the right cylinder head cover.
35. Disconnect the electrical connector (1) from the right Camshaft Position (CMP) sensor.
36. Disengage the wire harness retainer (3) from the intake manifold support bracket.
37. Disengage the wire harness retainer (2) from the upper intake manifold support bracket mounting stud.
38. Raise and support the vehicle Maintenance.
39. Remove both front tire and wheel assemblies (1) Tires And Wheels - Removal.
40. Remove the left lower splash shield (2).
41. Remove the right lower splash shield (2).
42. Remove both axle shafts (2) and the intermediate shaft Half Shaft - Removal.
43. Remove the front fore and aft crossmember (1) Crossmember - Removal.
44. Remove the crossunder pipe (2) Exhaust Crossunder Pipe - Removal.
45. Disconnect the oxygen sensor connectors from the main wire harness and remove both catalytic converters (3) Catalytic Converter - Removal.
46. Remove the three bolts (2) and the front engine mount bracket (1).
47. Remove the starter Starter - Removal.
48. Remove the lower radiator hose (1).
49. Remove the A/C compressor (1) from the engine compartment A/C Compressor - Removal.
50. Remove two bolts (1) and the rear engine mount heat shield (2).
51. Push back the heat shield (1) from the Crankshaft Position (CKP) sensor.
52. Disconnect the Crankshaft Position (CKP) sensor electrical connector (3).
53. Disengage one wire harness retainer (2) from the engine block and one wire harness retainer (1) from the transmission mounting stud.
54. Disengage the downstream oxygen sensor connector (4) from the engine mount.
55. Disconnect and reposition the power cord from the engine block heater (if equipped).
56. Remove three bolts (2) and the power steering pump heat shield (1).
57. Disengage the wire harness retainer (2) from the power steering pump.
58. Remove three bolts (1) and reposition the power steering pump and bracket as an assembly. Do not disconnect the power steering lines from the pump.
59. Disconnect the oil pump solenoid electrical connector (2).
60. Disengage the wire harness retainer (1) from the engine block.
61. Disengage three main wire harness retainers (1) from the right cylinder head cover.
62. Remove the bolt (3) from the rear engine mount isolator.
63. Remove four bolts (2) and the rear engine mount bracket (1).
NOTE: If the transaxle is to be eventually separated from the engine, removal of the torque converter bolts and lower transaxle mounting bolts are best accomplished at this time.
64. If required, remove the transaxle torque converter housing dust cover (1) and rubber plugs (2).
65. If required, remove the torque converter-to-driveplate bolts (1). Upon removing the bolts, a tight-tolerance (slotted) bolt will be encountered. Mark this location (flexplate and converter) with paint for assembly reference.
66. If required, remove the four transaxle-to-engine lower bolts (2).
67. Lower the vehicle.
68. Disconnect transmission solenoid harness connector (2).
69. Disengage the main wire harness retainer (1) from the valve body pan.
70. Disconnect the transmission input shaft speed sensor connector (1).
71. Disconnect the oil cooler lines (2) from transaxle using Trans Cooler Line Disconnect.
72. Disconnect the gearshift cable (1) from transaxle manual valve lever (2).
73. Disconnect the gearshift cable (5) from the bracket (4).
74. Disconnect two output shaft speed sensors connectors (2 and 3).
75. Disengage the wire harness retainer (1) from the gearshift cable bracket (4).
76. Reposition the main wire harness away from the engine.
77. Raise and position vehicle height to allow Power Train Dolly (3) and Engine Support Cradle (2) to be installed under the engine/transaxle assembly.
78. Loosen the cradle engine mounts to allow movement for positioning onto the engine locating holes on the engine block and oil pan rail. Place Adapter (1) on the front post and align to the oil pan mounting stud. Lower the vehicle and position cradle until the engine is resting on the posts. Tighten the post mounts to the cradle frame. Secure the engine/transaxle assembly to the dolly/cradle with safety straps (4).
79. Lower the vehicle so that the weight of the engine and transmission ONLY is on the cradle.
80. Remove two bolts (1) from the LH engine (transmission) mount bracket (2).
81. Remove three bolts (1) from the RH engine mount bracket (2).
82. 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.
NOTE: Perform the following steps to remove the transaxle from the engine if required.
83. Position a transmission jack under the transaxle. Secure the transaxle to the transmission jack.
84. Remove the remaining six transaxle upper bellhousing-to-block bolts (3).
85. Remove the transaxle (2) from the engine (1).
NOTE: Perform the following steps to remove the engine from the cradle/dolly fixture if required.
86. Remove the bolts (2) and remove the upper intake manifold support brackets (1).
87. Remove two bolts (2) and the heater core supply tube (1).
88. Install the Driver Side Engine Lifting Bracket (1) on the LH cylinder head with bolts (2) provided with the Engine Lifting Bracket. Tighten the bolts to 21 Nm (15 ft. lbs.).
89. Install the Passenger Side Engine Lifting Bracket (1) on the RH cylinder head with bolts (2) from the Engine Lifting Bracket. Tighten the bolts to 21 Nm (15 ft. lbs.).
90. Position a load-leveling lifting sling (2), such as OTC(R) 4305 Engine Load Leveler or equivalent, between the engine lifting brackets (3) and an engine hoist (1).
91. Remove the engine from the cradle/dolly fixture.
92. If required, remove the following components for installation on the replacement engine:
- Accessory drive belt tensioner
- Upper intake manifold support bracket
- Block heater (if equipped)