Removal Procedure

Engine Replacement (w/Automatic Transmission)


Tools Required
* J 42451-1 Engine Support Adapter
* 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 hood. Refer to Hood Replacement (Service and Repair) .
3. Recover the air conditioning (A/C) system. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging) .
4. Remove the drive belt. Refer to Drive Belt Replacement (Drive Belt Replacement) .
5. Remove the radiator. Refer to Radiator Replacement (Service and Repair) .
6. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Low Pressure Side with CH 48207) (Fuel Pressure Relief (Low Pressure Side with CH 48207))Fuel Pressure Relief (Low Pressure Side with CH 48027-100) (Fuel Pressure Relief (Low Pressure Side with CH 48027-100))Fuel Pressure Relief (Low Pressure Side w/o CH 48207) (Fuel Pressure Relief (Low Pressure Side w/o CH 48207))Fuel Pressure Relief (Low Pressure Side w/o CH 48027-100) (Fuel Pressure Relief (Low Pressure Side w/o CH 48027-100))Fuel Pressure Relief (High Pressure Side) (Fuel Pressure Relief (High Pressure Side)) .
7. 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) .
8. Disconnect the fuel feed pipe (1) from the fuel line. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service) .
9. 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) .
10. Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement (SKY) (Service and Repair)Air Inlet Grille Panel Replacement (Solstice) (Service and Repair) .
11. Remove the starter. Refer to Starter Motor Replacement (Service and Repair) .




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




13. Remove the charge air cooler pipe to turbocharger bolts (1).
14. Remove the charge air cooler pipe and gasket (2) from the turbocharger.
15. Cap or plug the turbocharger opening.




16. Reposition the radiator inlet hose clamp at the engine.
17. Remove the radiator inlet hose from the engine.
18. Reposition the radiator inlet hose out of the way.




19. Reposition the radiator outlet hose clamp (2) at the thermostat housing.
20. Reposition the radiator outlet hose clamp (1) at the oil cooler.
21. Remove the radiator outlet hose from the thermostat housing and oil cooler.
22. Remove the radiator outlet hose clip (3) from the bracket.
23. Reposition the radiator outlet hose out of the way.




24. Reposition the surge tank outlet hose clamp (2) at the thermostat housing.
25. Reposition the surge tank outlet hose clamp (1) at the oil cooler.
26. Remove the surge tank outlet hose from the thermostat housing and oil cooler.




27. Reposition the surge tank outlet hose clamp (2) at the surge tank.
28. Remove the surge tank outlet hose from the surge tank.
29. Remove the surge tank clip (1) from the oil level indicator tube bracket.
30. Remove the surge tank outlet hose from the vehicle.




31. Reposition the surge tank air bleed hose clamp (1) at the engine.
32. Remove the surge tank air bleed hose clip (3) from the surge tank bracket.
33. Remove the surge tank air bleed hose from the engine.
34. Reposition the air bleed hose out of the way.




35. Reposition the heater inlet and outlet hose clamps at the thermostat housing.
36. Remove the heater inlet (1) and outlet (2) hoses from the thermostat housing.
37. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair) .
38. Drain the engine oil.
39. Unbolt the catalytic converter from the exhaust pipe.




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




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




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




45. Cut the engine harness tie straps (1).
46. Remove the negative battery cable ground bolt (6) from the front engine lift bracket.
47. Remove the negative battery cable ground terminal (5) from the engine lift bracket.
48. Reposition the negative/positive battery cable out of the way.




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




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




51. Reposition the positive battery cable terminal boot (2).
52. Remove the generator terminal nut (1).
53. Remove the positive battery cable terminal (3) from the generator.
54. Disconnect the engine wiring harness electrical connector (4) from the A/C compressor.




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




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




57. Disconnect the engine wiring harness electrical connector (1) from the A/C refrigerant pressure sensor.




58. Disconnect the engine wiring harness electrical connector (1) from the brake booster vacuum sensor.




59. Disconnect the engine wiring harness electrical connector (1) from the windshield wiper motor.
60. Remove the engine harness clip (2) from the wiper motor hole.




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




64. Disconnect the engine wiring harness electrical connector (2) from the intake CMP actuator.
65. Disconnect the engine wiring harness electrical connector (1) from the exhaust CMP actuator.




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




67. Disconnect the engine wiring harness electrical connectors from the ignition coils.




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




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




72. Disconnect the engine harness clips (2) from the camshaft cover.
73. Disconnect the engine harness clip (1) from the camshaft cover.




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




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




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




79. Remove the engine harness clips (3, 4) from the front studs.
80. Gather all branches of the engine harness and lay off to the side.




81. Reposition the charge air bypass valve vacuum hose clamp (5) at the turbocharger.
82. Remove the vacuum hose from the turbocharger coolant feed pipe clips (4).
83. Remove the charge air bypass valve solenoid.




84. Remove the turbocharger coolant feed pipe bolt (1) at the turbocharger.
85. Remove the turbocharger coolant feed pipe fitting (2) from the cylinder head.
86. Remove the turbocharger coolant feed pipe bracket bolt from the cylinder head.
87. Remove the turbocharger coolant feed pipe bracket from the vehicle.




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




90. Remove the power steering pump bracket bolts and reposition the pump and bracket off to the side.




91. Remove the torque converter to flywheel bolts.

Important: The top 2 bellhousing bolts install through the bellhousing into the engine block. The remaining 7 bolts install through the engine block into the bellhousing.


92. Remove the 4 lower bellhousing bolts (2).
93. Lower the vehicle.
94. Remove the remaining upper 5 bellhousing bolts (1).




95. Remove the left engine mount upper nut.




96. Remove the right engine mount upper nut.
97. Install the J 42451-1 to the engine, if necessary.
98. Install a suitable engine lifting devise to the engine.
99. Separate the engine from the transmission.
100. Remove the engine from the vehicle.





Important: It may be necessary to remove the chamfer (bevel) from the edge of an 18 mm socket in order to get full engagement on the thin headed flywheel bolts.


101. Remove the flywheel bolts and flywheel.
102. Install the engine to an engine stand.




103. Remove the A/C compressor bolts and compressor.




104. Remove the catalytic converter to bracket bolts.




105. Remove the catalytic converter nuts (2).
106. Remove the catalytic converter (3) and gasket (1) from the turbocharger and bracket (4).