Engine - Removal

REMOVAL - ENGINE ASSEMBLY

1. Perform fuel pressure release procedure
2. Disconnect battery negative cable.
3. Remove air cleaner housing and inlet tube.
4. Disconnect the fuel line from fuel rail.
5. Disconnect all vacuum hoses.
6. Drain cooling system.
7. Remove radiator fans.
8. Remove radiator upper and lower hoses.

NOTE: When the transaxle cooler lines are removed from the rolled-groove type fittings at the transaxle, damage to the inner wall of the hose will occur. To prevent potential leakage, the cooler hoses must be cut off flush at the transaxle fitting, and a service cooler hose splice kit must be installed upon reassembly.

9. Using a blade or suitable hose cutter, cut transaxle oil cooler lines off flush with fittings. Plug cooler lines and fittings to prevent debris from entering transaxle or cooler circuit. A service splice kit will be installed upon reassembly.
10. Disconnect transmission shift linkage and electrical connectors.
11. Disconnect throttle body linkage.
12. Disconnect engine wiring harness.
13. Disconnect heater hoses from heater (Figure 1).




Figure 1 HEATER HOSES - 2.4L






14. Discharge air conditioning system.
15. Hoist vehicle and remove front wheels and tires.
16. Remove accessory drive belt splash shield.
17. Remove accessory drive belts.
18. Remove axle shafts.
19. Drain engine oil and remove oil filter.
20. Remove crossmember cradle plate (Figure 2).




Figure 2 Crossmember Cradle Plate


1 - CRADLE PLATE

21. Disconnect exhaust pipe from manifold (Figure 3).




Figure 3 Catalytic Converter to Exhaust Manifold






22. Remove engine front mount and bracket from engine.
23. Remove structural collar.
24. Remove rear engine mount bracket.
25. Mark flex plate to torque converter and remove torque converter bolts.
26. Pinch-off power steering supply hose at pump. Remove hose from pump.
27. Remove and set aside the power steering pump and bracket. Do not disconnect pressure line.
28. Lower vehicle.
29. Remove A/C lines at compressor and cap openings.
30. Remove engine ground straps (strap at engine right mount and at starter).
31. Raise vehicle enough to allow engine dolly Special Tool 6135, cradle Special Tool 6710 with Posts Special Tool 6848 to be installed under vehicle (Figure 4).
32. Loosen cradle posts to allow movement for proper positioning. Locate two rear posts (right side of engine) into the holes on the engine bedplate. Locate the two front posts (left side of engine) on the oil pan rails (Figure 4). Lower vehicle and position cradle mounts until the engine is resting on mounts. Tighten mounts to cradle frame. This will keep mounts from moving when removing or installing engine and transmission.
33. Install safety straps around the engine to cradle. Tighten straps and lock.
34. Lower vehicle so the weight of ONLY THE ENGINE AND TRANSMISSION are on the cradle.
35. Remove engine and transmission mount bolts.
36. Raise vehicle slowly. It may be necessary to move the engine/transmission assembly with the dolly to allow for removal around the body.




Figure 4 Positioning Engine Cradle Support Post Mounts