Engine Removal

Engine Removal

Special Tools Required
- Front sub-frame adapter EQS02C000011

NOTE:
- Use fender covers to avoid damaging painted surfaces.
- To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
- Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring or hoses, or interfere with other parts.

1. Secure the hood in the wide open position (support rod in the lower hole).
2. Make sure you have the anti-theft code for the radio, then write down the frequencies for radio's preset buttons.
3. Disconnect the negative cable from the battery first, then the positive cable.
4. Remove the battery.





5. Remove the intake manifold cover.





6. Disconnect the Intake Air Temperature (IAT) sensor connector (A), remove the breather hose (B), then remove the air cleaner housing (C).





7. Remove the intake air duct.





8. Remove the battery cables (A) from the under-hood fuse/relay box, then remove the harness clamps (B) and ground cable (C).





9. Remove the throttle cover (A). Fully open the throttle link and cruise control link by hand, then remove the throttle cable (B) and cruise control cable (C) from the links. Loosen the locknuts (D), and remove the cables from the bracket.





10. Disconnect the Engine Control Module (ECM)/ Powertrain Control Module (PCM) connectors (A) and main wire harness connector (B).





11. Remove the harness clamps (A) and grommet (B), then pull the engine wire harness through the bulkhead.
12. Relieve fuel pressure.
13. Disconnect the fuel feed hose.





14. Remove the Evaporative Emission (EVAP) canister hose (A) and brake booster vacuum hose (B).
15. Remove the clutch slave cylinder and clutch line bracket (M/T).
16. Remove the shift cable and select cable (M/T) (see step 7).
17. Remove the drive belt.





18. Remove the Power Steering (P/S) pump without disconnecting the P/S hoses.
19. Remove the radiator cap.
20. Raise the hoist to full height.
21. Remove the front tires/wheels.





22. Remove the splash shield.
23. Loosen the drain plug in the radiator to drain the engine coolant.
24. Drain the transmission fluid:
- Manual transmission.
- Automatic transmission.
25. Drain the engine oil





26. Disconnect air fuel ratio (A/F) sensor connector (A) and the Secondary Heated Oxygen Sensor (secondary H02S) connector(B), then remove the Three Way Catalytic Converter (TWC) assembly (C).
27. Separate the propeller shaft from the transfer assembly (4WD models) (see step 3).
28. Disconnect the stabilizer links.
29. Disconnect the suspension lower arm ball joints.
30. Remove the driveshafts. Coat all precision finished surfaces with clean engine oil. Tie plastic bags over the driveshaft ends.
31. Remove the shift cable (A/T).





32. Remove the lower hose.





33. Remove the Automatic Transmission Fluid (ATF) filter mounting bolt (A) (A/T).
34. Remove the ATF cooler hoses (B), then plug the ATF cooler hoses and lines (A/T).
35. Lower the hoist.





36. Remove the upper radiator hose (A) and heater hoses (B).





37. Attach the chain hoist to the engine as shown.








38. Remove the transmission mount bracket support bolt/nuts.





39. Remove the upper bracket mounting bolt and nut.
40. Make sure the hoist brackets are positioned properly. Raise the hoist to full height.





41. Remove the rear mount mounting bolts.





42. Remove the front mount mounting bolt.





43. Make the appropriate reference lines at positions A and B that line up with the center of the sub-frame mounting bolts (c).





44. Attach the special tool to the sub-frame with hanging the hook of the special tool over the front of the sub-frame, then tighten the special tool screw.
45. Raise the jack and line up the slots in the arms with the bolt holes on the corner of the jack base, then attach them with the bolts securely.





46. Remove the four sub-frame mounting bolts, then lower the sub-frame.





47. Disconnect the compressor clutch connector (A), then remove the A/C compressor (B) without disconnecting the A/C hoses.
48. Check that the engine/transmission is completely free of vacuum hoses, fuel and coolant hoses, and electrical wiring.
49. Slowly lower the engine about 150 mm (6 inch). Check once again that all hoses and wires are disconnected from the engine/transmission.
50. Lower the engine all the way. Remove the chain hoist from the engine.
51. Remove the engine from under the vehicle.