Removal
Engine Replacement^ Tools Required
- J 36346 Fascia Retainer Remover
- J 39g14 Serpentine Belt Tension Unloader
- J 43828 Ball Joint Separator
- J 44811 Accessory Belt Tensioner Unloader
- J 45341 Rear Wheel Drive Shaft Removal Tool
- SA91100CTie Rod Separator
- SA9127E Gage Bar Set
- SA9805E Fuel Line Separator
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the air Intake Temperature (IAT) sensor connector.
3. Loosen the clamp air cleaner assembly.
4. Remove the pushpin attachment from the outlet resonator/duct assembly to the support bracket.
5. Loosen the clamp at the throttle body assembly.
6. Disconnect the PCV fresh air vent hose at the cam cover.
7. Remove the outlet resonator/duct assembly.
8. Cover the throttle body opening with a shop towel. Use shop air to remove any dirt around the throttle body and intake manifold to cylinder head.
9. Remove the Underhood Fuse Block (UHFB) fuse cover by separating the clips on each side.
10. Remove the UHFB fuse cover.
11. Remove the inner UHFB fuse cover.
12. Loosen the three connectors through bolts (1) at the top of the UHFB.
13. Remove the battery and the electronic power steering feed wire connection nut and remove the wire from the UHFB stud.
14. Release the tabs on each side of the UHFB with a screwdriver.
15. Raise the UHFB from the connectors. Disconnect the electrical connectors on each side of UHFB.
16. Remove the UHFB from the vehicle.
17. Remove the battery cable and the harness attachment clips the on side of battery tray/UHFB bracket assembly.
18. Remove the main connectors from the UHFB housing.
19. Lay the battery positive cable wire over the engine. The battery cables will be removed with powertrain assembly.
20. Remove the electrical harness clips to battery tray.
21. Remove the UHFB and the battery tray bolts.
22. Remove the UHFB and the battery tray.
23. Disconnect the electrical connectors at the Transaxle Connector (TCM).
24. Remove the engine-to-body ground bolt.
25. Disconnect the connector for the rear 02 sensor.
26. Remove the vacuum hose with the check valve from the booster and lay across the engine.
27. Disconnect the 8-way electrical connector.
28. Remove the main engine harness Gray connector and lay over the engine assembly. This will allow the engine harness to be removed the with powertrain.
Notice: Do not remove the shifter cable from the bracket before removing the cable from the transaxle range switch. Damage to the manual shift linkage may occur.
29. If equipped with the automatic range transaxle, disconnect the shifter cable plastic retainer by using a screwdriver. Slightly pry between the shifter cable plastic retainer and the transaxle range switch.
Notice: Do not use too much force when disconnecting the shift cables or damage may result.
30. Disconnect the shift lever cables from the shift control housing by prying with even pressure using a J 36346 or equivalent manual transmission only.
31. Disconnect the shift lever cables from the shift lever cable bracket manual transmission only.
32. Disconnect the pressure line from the clutch actuator cylinder by removing the C-clip then pulling the line away from clutch actuator cylinder manual transmission only.
33. Disconnect the back-up lamp switch (1) and the front wheel speed sensor (2) manual transmission only.
Important: Place a shop towel on the generator to prevent coolant from entering the generator assembly.
34. Drain the coolant.
35. Disconnect the upper radiator hose at the engine cylinder head.
36. Disconnect the lower radiator hose at the coolant pipe.
37. Disconnect the degas hose at surge tank.
38. Disconnect the surge hose at the bottom of the surge tank.
39. Disconnect the heater hoses from the heater core at the front of the dash.
40. Relieve the fuel system pressure using the Fuel Pressure Relief Procedure.
41. Disconnect the SA9127E after the pressure has been relieved.
42. Remove the safety clip and disconnect the fuel line transfer line at the quick connect from the fuel line using the SA9805E.
43. Disconnect the purge hoses at the rear of the purge solenoid.
44. Remove the headlamp assemblies.
Important: The radiator/condenser/fan assembly will stay in the vehicle during engine removal.
45. Using long tie straps, secure the radiator/condenser fan assembly to the radiator support assembly.
Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.
46. Raise the vehicle.
47. Remove the front left-hand wheel.
48. Remove the front LH wheel inner splash shield.
Important: A piece of hardwood should be used between the transaxle case and cradle assembly. This wood will support the transaxle when the LH mount bolts are removed.
49. Install a piece of hardwood 1 x 2 x 4 between the transaxle case and the engine cradle assembly.
50. Remove the front right-hand (RH) wheel.
51. Remove the wheel inner splash shield.
Notice: Do not install wood under the oil pan plug boss. Damage to the oil pan may occur.
Important: A piece of hardwood should be used between the oil pan assembly and the engine cradle. This wood will support the engine when the right-hand mount bolts are removed.
52. Install a piece of hardwood 1 x 2 x 4 between the engine oil pan and engine cradle assembly near the crankshaft.
53. Install the accessory J 44811 tool onto the tensioner.
54. Remove the accessory drive belt.
55. Disconnect the electrical connector at the A/C compressor.
56. Disconnect the electrical connector at the A/C pressure transducer on-line.
57. Remove the A/C compressor bolts.
58. Support the compressor and the line assembly to the body with support straps.
59. Remove the pushpins that retain the air deflector assembly to the cradle.
Important: When the transaxle lines are disconnected, new seals must be installed into the transaxle to prevent the potential for leak.
Important: Fluid will leak when the lines are disconnected. Place a drip pan to collect the transaxle oil.
60. Drain the transaxle fluid.
61. if equipped with automatic, disconnect the transaxle lines from the transaxle.
62. Disconnect the rear 02 sensor.
63. Remove the exhaust pipe-to-manifold flange bolts.
64. Remove the exhaust pipe to intermediate pipe nuts.
65. Remove the converter pipe assembly and the support intermediate pipe assembly.
66. Remove the propshaft bolts to the Power Takeoff Unit (PTU)-AWD Only.
67. Remove the propshaft bolts at the rear axle assembly - AWD Only.
68. Remove the propshaft support bracket-to-body bolts - AWD Only.
69. Remove the propshaft assembly - AWD Only.
Notice: Do not remove the shifter cable from the bracket before removing the cable from the transaxle range switch. Damage to the manual shift linkage may occur.
70. If equipped with automatic, remove the shifter cable from the bracket assembly.
71. Remove the steering gear to the intermediate shaft bolt.
72. Remove the tie rod to knuckle nuts.
73. Separate the tie rod assemblies from the knuckle assemblies using the SA91100C.
74. Remove the lower control arm cotter pins and the nuts to knuckle assembly.
75. Separate the J 43828.
Important: The stabilizer links will stay in the vehicle connected to the strut assembly on the engine removal
76. Remove the lower stabilizer link nuts to the stabilizer bar.
77. Remove the left hand axle shaft assembly from the transaxle.
78. Disconnect the right-hand shaft assembly from the intermediate drive shaft using the J45341 tool with the appropriate slide tool.
79. Lower the vehicle.
80. Remove the right hand engine mount to the engine bracket bolts. The engine should rest on the wood blocks.
81. Remove the left hand transaxle mount to the transaxle bolts, the transaxle should rest on the wood blocks.
82. Raise the vehicle on the hoist.
Important: During the powertrain removal support the vehicle body by placing a jack at the rear of the vehicle.
83. Position the engine support table under the powertrain assembly.
Important: Blocks of wood can be used between the front of cradle and the oil pan to table to level powertrain during the removal.
84. With the table positioned, fully raise the table to contact with powertrain assembly.
85. Remove the cradle to body bolts
Important: When lowering the engine/transaxle assembly, verify all brake lines, shifter cable and other components are free during the removal.
86. Lower the engine table and raise the body on the hoist until the engine/transaxle and the cradle assembly is free from the vehicle.