Removal

Engine

WARNING: Before beginning any service procedure, REFER to Safety Warnings . Failure to follow this instruction may result in serious personal injury.

Special Tool(s)






Material(s)






Removal

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

1. With the vehicle in NEUTRAL, position it on a hoist. REFER to Lifting Points .

2. Recover the A/C (Air Conditioning) system. REFER to Air Conditioning (AC) System Recovery, Evacuation, and Charging .

3. Release the fuel system pressure. REFER to Fuel System Pressure Release .

4. Remove the 8 retainers and the underbody insulator.





5. Drain the cooling system. REFER to Cooling System Draining .

6. Remove the degas bottle. REFER to Degas Bottle .

7. Remove the battery tray. REFER to Battery and Battery Tray - Exploded View .

8. Remove the ACL (Air Cleaner) outlet pipe. REFER to Intake Air System Components - Exploded View and REFER to Air Cleaner Outlet Pipe - 2.0L GDI .

9. If equipped with automatic transmission, detach the transmission vent hose retainer from the crankcase vent tube.





10. Remove the nut and the generator power supply cable from the high current BJB (Battery Junction Box).





11. Detach the generator power supply cable retainer from the transmission.





12. Remove the PCM. REFER to Powertrain Control Module (PCM) .

13. NOTE: The electrical connector is located behind the PCM (Powertrain Control Module) case.
Disconnect the electrical connector.





14. Remove the 2 bolts and position the engine wiring harness ground cables aside.

- Detach the ground cable wiring harness retainer from the frame rail.






15. Disconnect the 2 wiring harness retainers from the transmission mount and frame rail.





16. Disconnect the wiring harness from the BJB (Battery Junction Box).





17. Disconnect the degas bottle coolant hose and upper radiator hose from the coolant connector.

- Detach the upper coolant hose retainer clip.






18. Disconnect the 2 heater coolant hoses from the heater core by turning the twist locks and remove.

- Remove the 2 coolant hoses from the retainer.






19. If equipped, disconnect the block heater electrical connector.






20. Remove the HO2S (Heated Oxygen Sensor) sensor. REFER to Heated Oxygen Sensor (HO2S) .

21. Disconnect the CMS (Catalyst Monitor Sensor) electrical connector.

- Detach the CMS (Catalyst Monitor Sensor) wire from the wiring harness retainer.






22. Remove the 4 bolts and the catalytic converter heat shield.

- Position the CMS (Catalyst Monitor Sensor) wiring harness bracket aside.






23. Remove the 2 bolts from the catalytic converter lower bracket.





24. Remove the 2 catalytic converter-to-muffler nuts.

- Discard the gasket.






25. Remove the 2 bolts for the catalytic converter hanger.





26. Remove the 5 catalytic converter manifold-to-cylinder head nuts and position the catalytic converter back.

- Discard the nuts and catalytic converter gasket.






27. Remove the 5 catalytic converter-to-cylinder head studs and discard.





28. Disconnect the fuel supply tube from the fuel injection pump. REFER to Quick Connect Coupling - Type 1 .





29. Disconnect the FTP (Fuel Tank Pressure) sensor electrical connector and the EVAP (Evaporative Emission) tube quick connect coupling. REFER to Quick Connect Coupling - Type 1 .





30. Disconnect the brake booster vacuum tube from the intake manifold and the position aside the vacuum tube.





31. If equipped with an automatic transmission, disconnect the transmission control cable from the manual control lever.






32. If equipped with an automatic transmission, remove the transmission control cable from the support bracket.






33. If equipped with an automatic transmission, disconnect the shift cable from the retainer.






34. If equipped with an automatic transmission, remove the 2 bolts and position the shift control cable and bracket aside.





35. NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

If equipped with a manual transmission, disconnect the clutch hydraulic line.





36. If equipped with a manual transmission, disconnect the gearshift cables and remove the 2 nuts and position aside the cable and bracket assembly aside.






37. Remove the RH and LH halfshafts. REFER to Halfshaft - RH and REFER to Halfshaft - LH .

38. Remove the A/C (Air Conditioning) tube support bracket bolt.





39. Remove the 2 nuts, the bolt and disconnect the A/C (Air Conditioning) tubes and position aside.

1. Discard the O-ring seals.






40. Disconnect the lower radiator hose from the radiator.





41. Remove the drain plug and drain the engine oil.

1. Install the drain plug and tighten to 27 Nm (20 lb-ft).






42. Remove and discard the oil filter.





43. Remove the cooling fan and shroud. REFER to Cooling Fan Motor and Shroud - 2.0L GDI .

44. NOTE: Automatic transmission shown, manual transmission similar.
Remove the 2 oil pan-to-transmission bellhousing bolts.





45. NOTE: Automatic transmission shown, manual transmission similar.
Remove the 2 transmission bellhousing-to-oil pan bolts.





46. Remove the 2 bolts and the roll restrictor mounting bracket.





47. NOTE: Position a block of wood under the transmission.
Position 300-OTC1585AE under the powertrain assembly and with 014-00001 attach the powertrain to the 300-OTC1585AE.






48. Remove the A/C (Air Conditioning) line from the engine mount clip and remove the clip.






49. Remove the 2 bolts, the 2 nuts and the engine mount.





50. Remove the transmission mount bolt.





51. Lower the powertrain from the vehicle.

52. Clean and inspect the catalytic converter flange. REFER to Exhaust Manifold Cleaning and Inspection .

53. If equipped with automatic transmission, disconnect the transmission wiring harness electrical connector.





54. Detach the battery power supply cable wiring harness retainer from the starter motor support bracket.





55. Remove the starter motor. REFER to Starter Motor - 2.0L GDI .

56. Remove the starter motor isolator.





57. NOTICE: Rotate the engine in a clockwise direction only or engine damage may occur.

NOTE: To prevent the flexplate-to-clutch nuts from falling into the clutch housing and causing damage, use a magnetic socket to install the 6 flexplate-to-clutch nuts.

NOTE: Index mark one stud and the clutch for assembly reference.
If equipped with automatic transmission, remove and discard the 6 clutch-to-flexplate nuts.





58. Using 300-OTC1819E and 303-D089 (D93P-6001-A3) , remove the engine and transaxle from the lift table.





59. NOTE: Automatic transmission shown, manual transmission similar.
Remove the 2 rear engine-to-transmission bolts.





60. Remove the nut and the ground cable.





61. NOTE: Automatic transmission shown, manual transmission similar.
If equipped with a automatic transmission, remove the 4 bellhousing-to-engine fasteners. If equipped with a manual transmission, remove the 5 bellhousing-to-engine fasteners.

- Separate the transaxle from the engine.