Engine - Removal

REMOVAL - ENGINE ASSEMBLY





1. Release fuel pressure Service and Repair.
2. Disconnect negative battery cable.
3. Drain cooling system.
4. Remove both front wheels (1).




5. Discharge A/C system using a suitable refrigerant recovery machine.
6. Remove throttle body air inlet hose (1) and air cleaner housing assembly Air Cleaner Housing - Removal.




7. Remove left and right splash shields (2) Front Wheelhouse Splash Shield - Removal.




8. Remove front fascia closeout (1) Removal.




9. Disconnect upper (2) and lower radiator hoses at radiator.




10. Automatic Transmission Equipped Vehicles:
- Remove the transaxle oil cooler lines. Plug lines and fittings to prevent debris from entering transaxle or cooler circuit.
- Disconnect transmission electrical harness connectors.
- Disconnect transmission shift cable.

11. Disconnect A/C lines (1) at condenser.




12. Manual Transmission Equipped Vehicles:
- Disconnect transmission shift cables and remove from retaining bracket.
- Disconnect back up lamp switch connector.

13. Disconnect A/C lines (1) at condenser.




14. Disconnect the hose from the engine to the coolant recovery container (2).
15. Remove cooling module (fan, radiator, A/C condenser).
16. Remove fasteners attaching ABS brake module to lower radiator crossmember. Support module with a suitable retaining strap.




17. Disconnect engine electrical harness from PCM and bulkhead connectors.
18. Disconnect brake line from retaining clips that attach to lower radiator crossmember.
19. Disconnect hose from the radiator to the coolant recovery container (3).




20. Remove the propeller shaft to ptu fasteners (2). (If equipped) Propeller Shaft - Removal.




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




22. Remove front engine mount thru bolt (1). Remove front engine mount (3) from lower radiator crossmember.




23. Remove lower radiator crossmember (2).




24. Remove accessory drive belts (2) Accessory Drive Belt - Removal.




25. Remove power steering belt (2) Accessory Drive Belt - Removal.




26. Remove power steering pump and bracket (1) as an assembly. Do not disconnect power steering lines from pump. Reposition pump and support with suitable retaining strap Power Steering Pump - Removal.
27. Disconnect heater return hose from pipe connection at right front frame rail area.




28. Disconnect A/C compressor electrical connector (1).




29. Remove A/C compressor mounting bolts (2). Reposition A/C compressor (1) and support with suitable retaining strap. Generator can be removed with engine assembly.




30. Remove structural collar (1) Removal.




31. Drain engine oil.
32. Remove the exhaust cross-under pipe (4) Cross Pipe - Removal.




33. Automatic Transmission Equipped Vehicles:
34. Remove bolt (1) from rear engine mount and transaxle bracket.
- Remove transaxle torque converter housing cover.
- Mark flex plate to torque converter position. Remove torque converter bolts.





35. Manual Transmission Equipped Vehicles:
36. Remove bolt (1) from rear engine mount and transaxle bracket.
- Using Special Tool 6638, disconnect clutch hydraulic circuit quick connect fitting.
- Remove clutch/drive plate inspection cover.
- Mark flex plate to modular clutch position. Remove modular clutch assembly-to-drive plate bolts.





37. Disconnect positive cable from battery and PDC.
38. Disconnect ground cable from left side transaxle mount bracket.
39. Disconnect ETC connector (2) from throttle body.




40. Disconnect ground strap at right shock tower.
41. Disconnect fuel line.
42. Disconnect brake booster and vapor purge vacuum hoses.
43. Disconnect all ground straps attaching to engine.




44. Position vehicle height to allow engine dolly 6135 (2) and cradle 6710 (3) with posts 6848 to be installed under vehicle.
45. Loosen cradle engine mounts to allow movement for positioning onto engine locating holes on the engine block, compressor mount bracket and oil pan rail. Lower vehicle and position cradle until the engine is resting on posts. Tighten post mounts to cradle frame to prevent movement when removing or installing engine/transaxle assembly. Secure engine/transaxle assembly to dolly/cradle with safety straps (1).




46. Lower vehicle so weight of the engine and transmission ONLY is on the cradle (2).
47. Remove right and left side engine mount bolts.
48. Slowly raise 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.