Engine - Removal

REMOVAL - ENGINE ASSEMBLY





1. Perform fuel pressure release procedure, then disconnect and remove fuel line.
2. Remove air cleaner housing assembly (2) and clean air hose (1)Air Cleaner Housing - Removal.




3. Disconnect both cables from battery.
4. Remove battery and battery tray (1) Battery - Removal.
5. Disconnect battery temperature sensor.




6. Drain cooling system.
7. Discharge air conditioning system, if equipped.




8. Remove throttle cable cover.
9. Disconnect throttle and speed control cables from throttle body.
10. Disconnect engine wiring harness at Powertrain Control Module (PCM).




11. Disconnect positive cable from Power Distribution Center (PDC) (1) and ground wire from vehicle body. Remove bolts attaching PDC (2) and set aside.
12. Disconnect wiring connectors at lower battery tray support.




13. Disconnect ground wire (1) from the vehicle body-to-engine at the right side strut tower.
14. Disconnect brake booster vacuum hose from intake manifold.
15. Disconnect the proportional purge hose from throttle body.
16. Disconnect coolant reserve/recovery hose from coolant outlet connector.
17. Disconnect heater hoses.




18. Remove grill (2)Grille - Removal.




19. Remove upper radiator closure (1) and center brace (2)Removal.
20. Remove upper radiator hose.
21. Remove lower radiator hose.
22. Remove thermostat housing.




23. Disconnect upper A/C line from A/C condenser.
24. Disconnect A/C lines at junction near upper torque strut.
25. Automatic Transmission equipped vehicles:
a. Using a blade or suitable hose cutter, cut transaxle oil cooler lines off flush with transmission fittings. Plug lines and fittings to prevent debris from entering transaxle or cooler circuit. A service splice kit will be installed upon reassembly.
b. Disconnect transmission electrical connectors.
c. Disconnect transmission shift linkage.




26. Manual Transmission equipped vehicles:
a. Using Special Tool 6638A (2), disconnect clutch hydraulic line.
b. Disconnect transmission shift linkage.
c. Disconnect transmission electrical connectors.
27. Turbocharger equipped vehicles: Disconnect power steering hoses from radiator.
28. Disconnect radiator fan electrical connector and remove cooling module assembly (fan, radiator, A/C condenser, transmission oil cooler).
29. Hoist vehicle and remove front wheels.
30. Remove right and left inner splash shields.
31. Remove both axle shafts Half Shaft - Removal.
32. Remove accessory drive belts Accessory Drive Belt - Removal.
33. Remove generator and support brackets.




34. Turbocharger equipped vehicles: Remove charge air cooler hoses (1 & 3).
35. Drain engine oil.




36. Disconnect the downstream oxygen sensor connector.
37. Disconnect exhaust system from manifold (1).




38. Non-Turbo equipped vehicles: Disconnect power steering pressure hose (3) from steering gear (1).




39. Turbocharger equipped vehicles: Disconnect both power steering hoses (3 & 5) from steering gear (1).




40. Turbocharger equipped vehicles: Remove upper and lower heat shields (1), elbow support bracket (4), turbocharger support bracket (2), and elbow (3).
41. Remove structural collar Removal.
42. Automatic Transmission equipped vehicles:
a. Remove torque converter bolts and mark converter to flex plate orientation for reassembly.
43. Manual Transmission equipped vehicles:
a. Remove drive plate to clutch module bolts and mark plate orientation for reassembly.




44. Remove lower engine torque strut (5)Torque Strut - Removal.
45. Lower vehicle and remove A/C compressor.
46. Disconnect power steering lines from power steering pump.
47. Remove power steering pump.




48. Raise vehicle enough to allow engine dolly (7), cradle (8), and posts (6), to be installed under vehicle. For Special Tool identification Tools and Equipment.
49. Loosen engine support posts (6) to allow movement for positioning onto engine locating holes and flange on the engine bedplate. Lower vehicle and position cradle (8) until the engine is resting on support posts (6). Tighten mounts to cradle (8) frame. This will keep support posts (6) from moving when removing or installing engine and transmission.
50. Install safety straps (4) around the engine to cradle (8). Tighten safety straps (4) and lock them into position.

WARNING: Safety straps MUST be used.

51. Raise vehicle enough to determine if safety straps (4) are secure enough to hold cradle (8) assembly to engine.
52. Lower vehicle so weight of the engine and transmission ONLY is on the cradle (8) assembly.




53. Remove the upper engine torque strut.
54. Remove right mount through bolt (1).




55. Remove left mount (3) attaching bolts.
56. Raise vehicle slowly until engine/transaxle assembly clears engine compartment. It may be necessary to move the engine/transmission assembly with the cradle to allow for removal around body flanges.