Engine - Removal

REMOVAL - ENGINE ASSEMBLY

1. Perform fuel pressure release procedure.
2. Disconnect negative battery cable.
3. Remove air cleaner and hoses.
4. Disconnect the fuel line from fuel rail.
5. Remove the wiper module.
6. Block off heater hoses to the rear heater system using pinch-off pliers (if equipped).
7. Drain the cooling system.
8. Disconnect the heater hoses.
9. Remove the radiator upper support crossmember.
10. Remove the radiator fans.
11. Disconnect the throttle cables from the throttle body.
12. Disconnect the MAP, IAC, and TPS electrical connectors.
13. Disconnect the EGR transducer electrical connector (if equipped).
14. Disconnect the vacuum hoses from throttle body.
15. Disconnect the brake booster and speed control vacuum hoses.
16. Disengage wire harness clip from the right side engine mount.
17. Remove the power steering reservoir from mounting position and set aside. Do not disconnect hose.
18. Disconnect ground strap from rear of cylinder head.
19. Disconnect engine coolant temperature (ECT) sensor and ignition coil electrical connectors.
20. Disconnect the fuel injector electrical harness connector and disengage clip from support bracket.
21. Disconnect camshaft and crankshaft position sensor electrical connectors.
22. Evacuate air conditioning system.
23. Disconnect A/C compressor electrical connector.
24. Disconnect the A/C lines from compressor. Cover and seal all openings of hoses and compressor.
25. Remove the radiator upper hose.
26. Disengage electrical harness clip at transaxle dipstick tube.
27. Remove transaxle dipstick tube. Seal opening using a suitable plug.

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 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.

28. 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.
29. Disconnect transaxle shift linkage and electrical connectors.
30. Raise vehicle on hoist and drain the engine oil.
31. Remove the axle shafts.
32. Remove crossmember cradle plate (Figure 1).




Figure 1 Crossmember Cradle Plate


1 - CRADLE PLATE

33. AWD equipped: Remove the power transfer unit (PTU).
34. Disconnect exhaust pipe from the manifold (Figure 2).




Figure 2 Catalytic Converter to Exhaust Manifold






35. Remove front engine mount and bracket as an assembly.
36. Remove the engine rear mount bracket.
37. Remove the engine to transaxle struts (Figure 3).




Figure 3 POWERTRAIN SUPPORTS AND DUST COVER






38. Remove transaxle case cover (Figure 3).
39. Remove flex plate to torque converter bolts. Mark torque converter to flex plate for orientation for reassembly.
40. Remove the power steering pressure hose support clip attaching bolt.
41. Disconnect the knock sensor electrical connector (3.8L only).
42. Disconnect the engine block heater electrical connector (if equipped).
43. Remove the accessory belt splash shield.
44. Remove accessory drive belt.
45. Disconnect the radiator lower hose.
46. Remove air conditioning compressor from engine.
47. Remove the generator.
48. Remove the water pump pulley attaching bolts and position pulley between pump hub and housing.
49. Disconnect the oil pressure switch electrical connector.
50. Disconnect wiring harness support clip from engine oil dipstick tube.
51. Install Special Tools 6912 and 8444 Adapters on the right side (rear) of engine block (Figure 4).




Figure 4 ADAPTER TOOLS MOUNTED ON BLOCK






52. Lower the vehicle.
53. Remove the power steering pump and set aside.
54. Raise vehicle enough to allow engine dolly Special Tool 6135 and cradle Special Tool 6710 with post Special Tool 6848 and adaptor Special Tool 6909 to be installed under vehicle (Figure 7).
55. Loosen cradle/post mounts to allow movement for positioning posts into locating holes on the engine (Figure 5) and (Figure 6). Slowly lower vehicle and position cradle/post mounts until the engine is resting on posts. Tighten all cradle/post mounts to cradle frame. This will keep mounts from moving when removing or installing engine and transmission.




Figure 5 Positioning Special Tool 6848 for use with Adapters 8444 & 6912










Figure 6 Special Tools 6848 with Adapters 6909






56. Lower vehicle so the weight of ONLY THE ENGINE AND TRANSMISSION is on the cradle.
57. Install and secure the safety straps to the cradle fixture and around the engine (Figure 7).
58. Remove the engine right side mount to engine attaching bolts.
59. Remove the left mount through bolt.
60. Raise vehicle slowly. It is necessary to move the engine/transmission assembly with the dolly to allow for removal around body flanges.




Figure 7 Positioning Engine Cradle Support Post Mounts