Engine - Removal - Manual Transaxle

Engine - Manual Transaxle





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. For additional information, refer to Jacking and Lifting Service and Repair.

2. Release the fuel system pressure. For additional information, refer to Fuel System - General Information Service and Repair.

3. Remove the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to Intake Air Distribution and Filtering - 2.5L Air Cleaner and Air Cleaner Outlet Pipe.

4. Recover the A/C system. For additional information, refer to Climate Control System - General Information and Diagnostics Air Conditioning (A/C) System Recovery, Evacuation and Charging.

5. Remove the battery tray. For additional information, refer to Battery, Mounting and Cables Battery Tray.

6. Remove the 2 nuts and the battery cables from the positive battery cable.





7. Disconnect the engine wiring harness electrical connector.





8. Remove the bolt and the ground wire from the body.





9. Detach the 2 negative battery cable pin-type retainers from the transaxle mount and battery tray bracket.





10. Disconnect the 2 engine harness electrical connector.





11. Use a steering wheel holding device (such as Hunter(R) 28-75-1 or equivalent).
- Using a suitable holding device, hold the steering wheel in the straight-ahead position.





12. Remove the 2 nuts and the steering joint cover.





13. NOTICE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring can occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to Supplemental Restraint System Service and Repair.

Remove the bolt and disconnect the steering column shaft from the steering gear.

- Discard the bolt.





14. If equipped, remove the 7 screws and the underbody cover.





15. Drain the cooling system. For additional information, refer to Engine Cooling Service and Repair.

16. NOTICE: The steering gear-to-dash seal must be removed or it will be damaged when lowering the subframe.

Release the 4 clips (2 shown) and slide the steering gear-to-dash seal off of the steering gear and into the passenger compartment.





17. Remove the engine roll restrictor bolt.





18. Remove the 4 screws and position the RH fender splash shield aside.





19. Remove the 6 pin-type retainers (4 shown) and the RH splash shield.





20. Remove the 4 screws and position the LH fender splash shield aside.





21. Remove the 6 pin-type retainers (4 shown) and the LH splash shield.





22. Remove the LH halfshaft and the intermediate shaft.

23. Disconnect the 2 Electronic Power Assist Steering (EPAS) system electrical connectors.





24. Detach the 2 EPAS system wiring harness pin-type retainers from the subframe.





25. Detach the EPAS system wiring harness pin-type retainer from the subframe under the LH fender splash shield.





26. Remove the bolt and the EPAS system wiring harness ground.





27. NOTE: LH shown, RH similar.

Remove the cotter pins and nuts from the tie-rod ends.





28. NOTE: LH shown, RH similar.

Using the Tie-Rod End Remover, separate the tie-rod ends from the steering knuckles.





29. NOTE: LH shown, RH similar.

Remove the nuts and separate the sway bar links from the struts.





30. Position the Powertrain Lift under the subframe assembly.





31. NOTE: LH shown, RH similar.

Remove the subframe bracket-to-body bolts.





32. NOTE: LH shown, RH similar.

Remove the rear subframe nuts and the subframe brackets.





33. NOTE: LH shown, RH similar.

Remove the front subframe nuts.





34. Lower the subframe assembly from the vehicle.

35. Remove the engine oil pan drain plug and drain the engine oil.
- Install the drain plug and tighten to 28 Nm (21 lb-ft).





36. Remove the engine oil filter.

37. Remove the exhaust flexible pipe. For additional information, refer to Exhaust System Exhaust Flexible Pipe.

38. Disconnect the crankcase vent tube from the valve cover.





39. Depress the locking ring and disconnect the brake booster vacuum supply tube from the intake manifold.





40. Disconnect the fuel vapor return tube.





41. Disconnect the fuel supply tube quick connect coupling. For additional information, refer to Fuel System - General Information Quick Connect Coupling.





42. Detach the coolant hose retainer.





43. Disconnect the upper radiator and heater hoses from the coolant outlet and disconnect the heater hose in-line connector.





44. Disconnect the transaxle control cables from the control levers.
- Detach the control cables from the bracket.





45. Remove the 2 clutch tube bracket bolts.





46. Remove the 2 bolts and position the clutch slave cylinder aside.





47. Remove the bolt and the ground wire from the engine mount.





48. Remove the A/C tube/windshield washer reservoir bracket bolt.





49. Remove the nut and disconnect the A/C tube.
- Discard the O-ring seal.





50. Detach the coolant vent hose retaining clip from the A/C tube.





51. Remove the nut and disconnect the upper A/C tube from the condenser.
- Discard the O-ring seal.





52. Detach the Knock Sensor (KS) electrical connector from the intake manifold.





53. Remove the lower radiator hose from the thermostat housing.





54. If equipped, position the block heater shield aside and disconnect the block heater electrical connector.
- Detach the 8 block heater wiring harness retainers (1 shown) and remove the block heater wiring harness.





55. Detach the lower radiator hose pin-type retainer from the cooling fan shroud.





56. Remove the bellhousing-to-oil pan bolt.





57. Remove the 2 oil pan-to-bellhousing bolts.





58. NOTE: Position a block of wood under the transaxle.

Install the Powertrain Lift and Universal Adapter Brackets onto the engine.

- Raise the engine and transaxle 25.4 mm (1 in) to neutralize the engine and transaxle mounts.





59. Remove the 2 transaxle mount bolts.





60. Remove the bolt, 2 nuts and the motor mount bracket.





61. Lower the engine and transaxle from the vehicle.

62. Disconnect the A/C compressor electrical connector.





63. Detach the A/C compressor wiring harness pin-type retainer from the intake manifold.





64. Remove the 2 nuts and disconnect the starter wires.





65. Remove the nut from the starter motor stud bolt.





66. Remove the bolt, stud bolt and the starter.





67. Remove the starter motor isolator.





68. Press the locking tab to release the generator air duct and remove.





69. Disconnect the generator electrical connection.





70. Remove the nut and the generator wiring harness.





71. Detach the 4 wiring harness retainers (3 shown) from the valve cover stud bolts.





72. Install the Heavy Duty Floor Crane and Spreader Bar and remove the engine and transaxle from the Powertrain Lift table.





73. Remove the bellhousing-to-engine retainers.
- Separate the engine and transaxle.