Removal

Engine Replacement (M35)
The following procedure requires the removal of the engine and transmission as an assembly.


Tools Required
- J 38185 Hose Clamp Pliers

Removal Procedure
1. Remove the hood.
2. Remove the wiper motor module.
3. Remove the fasteners securing the front air inlet panel to the battery tray and cowl.
4. Remove the front air inlet panel from the vehicle.
5. Disconnect the battery negative cable.







6. Remove the bolt (1) securing the battery negative cable to the side rail.
7. Disconnect the body harness connector (3) from the battery negative cable and secure to the engine.







8. Depress the tabs in order to remove the underhood fuse block cover from the underhood fuse block.







9. Remove the nut (1) securing the battery positive cable (2) to the underhood fuse block.
10. Disconnect the battery positive cable from the battery and secure to the engine.
11. Disconnect the engine wiring harness electrical connector from the underhood fuse block and secure to the engine.
12. Remove the air cleaner assembly.
13. Remove the intake air resonator.
14. Disconnect the engine wiring harness connector at the right shock tower and secure to the engine.







15. Disconnect the engine wiring harness connector (1) from the coolant bypass solenoid.







16. Remove the bolt securing the engine wiring harness ground lead to the right body rail.
17. Drain the cooling system.







18. Position the J 38185 to the clamps in order to remove the surge tank inlet hose from the following:
- The radiator
- The throttle body assembly

19. Remove the inlet radiator hose.
20. Remove the outlet radiator hose.







21. Position the J 38185 to the clamp (2) in order to remove the coolant bypass outlet hose from the coolant inlet pipe.







22. Position the J 38185 to the clamp (1) in order to remove the coolant bypass inlet hose from the afterboil coolant pump pipe.
23. Relieve the fuel system pressure.







24. Refer to Quick Connect Fitting(s) Service (Metal Collar) in order to disconnect the following quick connect fittings from the fuel rail:
- The return hose/pipe (1)
- The feed hose/pipe (2)
Plug the open outlet ports to prevent fuel loss and contamination.

25. Disconnect the evaporative emission (EVAP) quick connect fitting (3).
26. Open the retainer (4) located at the engine control module (ECM) bracket in order to remove the chassis hose/pipes.







27. Position the J 38185 to the clamp (1) in order to remove the outlet heater hose from the afterboil coolant pump (2).







28. Position the J 38185 to the clamp (1) in order to remove the inlet heater hose from the heater core.
29. Position the J 38185 to the clamp in order to remove the surge tank outlet hose from the surge tank and secure to the engine.







30. Disconnect the electrical connector (1) from the Air Conditioning (A/C) refrigerant pressure sensor (2).
31. Disconnect the 2 engine wiring harness connectors from the left body rail connectors.







32. Remove the power steering return hose nut and retainer from the A/C compressor stud.







33. Disconnect the retainer (1) securing the engine wiring harness to the A/C pressure hose and secure to the engine.







34. Remove the power steering pressure hose nut and retainer from the A/C compressor stud.
35. Remove the drive belt.







36. Remove the power steering pump mounting bolts ONLY.
37. Remove the power steering pump from the accessory mounting bracket, and position aside.







38. Disconnect the following from the remote power steering fluid reservoir (1):
- The vacuum brake booster hose
- The wiring harness (2)

39. Disconnect the vacuum brake booster hose from the vacuum source.







40. Remove the remote power steering fluid reservoir mounting bolts (1, 3) ONLY, and position aside.







41. Disconnect the electrical connector from the A/C compressor.

Important: Evacuation of the A/C refrigerant will not be necessary.

42. Remove the A/C compressor mounting bolts ONLY, and position aside.
43. Raise and support the vehicle.

44. Remove the exhaust system.
45. Remove the left and right catalytic converters.
46. Remove the catalytic converter hanger bracket.







47. Remove the Electronic Brake Control Module (EBCM) connector position assurance retainer (4) from the EBCM electrical connector (1).
48. Rotate the EBCM connector tab (2) up into the unlocked position.
49. Disconnect the EBCM electrical connector (1) from the EBCM (3).
50. If equipped, disconnect the electrical connector from the brake fluid pressure sensor.







51. Disconnect the Antilock Brake System (ABS) wiring harness electrical connectors from the left and right wheel speed sensors.

Important: Note the routing of the ABS wiring harness.







52. Remove the ABS wiring harness retainers from the following:
- The lower control arms
- The electric cooling fan







53. Remove the ABS wiring harness retainers (2) from the engine frame.
54. If equipped, disconnect the variable effort steering electrical connector (1) from the power steering gear pigtail.
55. Drain the engine oil.
56. Remove the oil filter adapter.







57. Remove the right engine mount upper retaining nut.







58. Remove the left engine mount upper retaining nut.







59. Remove the clutch hydraulic hose retaining clip (1) from the clutch slave cylinder.
60. Pull the clutch hydraulic hose (2) from the clutch slave cylinder.
It is not necessary to plug the lower hose end or slave cylinder fitting as they are equipped with check valves. Only minimal fluid loss may be experienced.







61. Disconnect the propeller shaft coupler (1) from the transmission flange ONLY and secure to the shift reaction arm using mechanics wire.
62. Support the rear of the transmission using a suitable screw jack.
63. Remove the transmission support.
64. Carefully lower the transmission only enough to access the shift control pins.







65. Remove the shift control pin retaining clips (1).
66. Remove the retaining pin (5) from the transmission and disconnect the shift reaction arm (4).
67. Remove the retaining pin (3) from the transmission and disconnect the shift control arm (2).

Important: This will support the transmission while the vehicle is lowered.

68. Install the transmission support to the vehicle.







69. Install the outer transmission support mounting bolts. Do not tighten.
70. Lower the screw jack fully.
71. Remove the screw jack from under the transmission.
72. Lower the vehicle.
73. Using a lift jack support the rear of the transmission.
74. Remove the outer transmission support mounting bolts.







75. Remove the transmission support from the vehicle.







76. Install an engine lift chain to the engine lift brackets and attach to an engine lift devise.

Important: Ensure clearance is maintained between the engine/transmission assembly and the following:
- The A/C compressor
- The A/C hoses
- The brake pipes at the BPMV
- The coolant bypass valve
- The electric cooling fans
- The engine wiring electrical harness
- The fuel hoses
- The power steering pump
- The radiator
- The remote power steering fluid reservoir
- The vehicles tunnel

77. Alternate between the following in order to remove the engine/transmission assembly from the engine compartment:
- Carefully raise the engine/transmission assembly using the engine lift devise.
- Lower the lift jack supporting the rear of the transmission enough to clear the vehicles tunnel.

78. Lower the engine/transmission assembly to the floor.

Important: The following are on-vehicle procedures, use only the portion of the procedure needed for removal of the component.

79. Remove the following components from the engine if necessary:
- Afterboil Coolant Pump Replacement
- Battery Negative Cable Replacement
- Battery Positive Cable Replacement
- Coolant Heater Cord Replacement
- Coolant Pipe Replacement - Inlet
- Generator Replacement
- Starter Motor Replacement
- Surge Tank Hose/Pipe Replacement - Outlet
- Throttle Body Heater Hose/Pipe Replacement - Inlet







80. Remove the 2 bolts (2-4) securing the engine wiring harness ground leads (1-3) to the left cylinder head.







81. Remove the bolt securing the engine wiring harness retainer to the oil pan.







82. Remove the right engine mount retaining bolts and bracket.







83. Remove the left engine mount retaining bolts and bracket.
84. Disconnect the engine wiring harness retainers.
85. Disconnect the engine wiring harness connectors from the electrical components.







86. Disconnect the engine wiring harness retaining clips (1) from the transmission mounting bolts.

Important: Note the routing of the engine wiring harness.

87. Remove the engine wiring harness from the engine.







88. Remove the transmission mounting bolts (1, 2 and 4).







89. Remove the remaining transmission mounting bolts (2-4).
90. With the aid of an assistant remove the transmission from the engine.
91. Remove the engine lift chain from the engine.