Removal Procedure

Engine Replacement

Removal Procedure




1. Ensure that the tires are in the straight forward position, remove the key from the ignition.
2. Raise the hood.
3. Disconnect the negative battery cable.
4. Relieve the fuel system pressure.
5. Disconnect the fuel feed line quick connect fitting (4) from the fuel rail.
6. Disconnect the evaporative emission (EVAP) line quick connect fitting (3) from the EVAP purge solenoid.
7. Remove the fuel line clips (1, 2) from the engine brackets.




8. Drain the cooling system.
9. Secure the cooling module to the upper body structure.
10. Remove the engine drive belt.




11. Disconnect the cooling fan electrical connector.




12. Reposition the radiator inlet hose clamp at the engine.
13. Remove the radiator inlet hose from the engine.




14. If the vehicle is equipped with a engine oil cooler perform the following steps, otherwise proceed to step 19.
15. Reposition the radiator outlet hose clamp (1) at the water outlet.
16. Reposition the radiator outlet hose clamp (2) at the oil cooler.
17. Remove the radiator outlet hose from the water outlet.
18. Remove the radiator outlet hose from the oil cooler. Proceed to step 23.




19. If the vehicle is not equipped with a engine oil cooler, reposition the surge tank outlet hose clamp at the surge tank.
20. Remove the surge tank outlet hose from the surge tank.




21. Reposition the radiator outlet hose clamp (1) at the thermostat cover.
22. Remove the radiator outlet hose from the thermostat cover.




23. Reposition the heater inlet and outlet hose clamps at the thermostat housing.
24. Remove the heater inlet and outlet hoses (1, 2) from the thermostat housing.




25. Reposition the brake booster vacuum hose clamp (2) at the intake manifold.
26. Remove the brake booster vacuum hose from the intake manifold. Reposition the hose.




27. Disconnect the following electrical connectors:
^ Throttle actuator control (TAC) (1)
^ Manifold absolute pressure (MAP) sensor
^ Fuel injector harness (2)
^ Generator (3)




28. Disconnect the engine harness clip (2) from the oil level indicator tube.
29. Disconnect the engine harness clips (1, 3, 4) from the intake manifold.




30. Disconnect the ignition coils electrical connectors (1).
31. Disconnect the intake (3) and exhaust (2) camshaft position actuator electrical connectors.




32. Remove the engine harness clips (1) from the camshaft cover.




33. Remove the negative battery cable ground nut (4).
34. Remove the engine harness ground terminal (3) from the stud.
35. Remove the negative battery cable ground terminal (2) from the stud.
36. Remove the stud (1).
37. Remove the engine harness ground terminals (5).




38. Disconnect the following engine harness electrical connectors:
^ Oil pressure sensor (4)
^ Crankshaft position (CKP) sensor (6)
^ Knock sensor (5)




39. Disconnect the EVAP purge solenoid electrical connector (2).
40. Remove the engine harness clip (1) from the purge solenoid bracket.




41. Remove the engine harness ground bolt.
42. Reposition the engine harness ground terminal.




43. Disconnect the engine harness electrical connector (1) from the air conditioning (A/C) pressure switch.
44. Disconnect the engine harness electrical connector (2) from A/C compressor.
45. Unbolt and reposition the AC compressor aside.
46. Raise and suitably support the vehicle.
47. Drain the engine oil.




48. Remove the transaxle fluid cooler bracket nut.
49. Remove the transaxle fluid cooler lines from the transaxle.




50. Remove the engine harness clip nut (3) from the engine stud.
51. Remove the engine harness clip (1) from the stud.
52. If equipped with a automatic transaxle, disconnect the engine harness electrical connector (2) from the vehicle speed sensor (VSS).
53. Remove the engine harness clip (3) from the speed sensor.




54. Remove the positive battery cable lead nut (4) from the starter solenoid.
55. Remove the positive battery cable terminal (3) from the starter.
56. Remove the engine harness to starter solenoid "S" terminal nut (2).
57. Remove the engine harness lead terminals (1) from the starter solenoid.




58. Lower the vehicle.
59. Reposition the engine harness boot (3).
60. Remove the generator nut (2).
61. Remove the engine harness lead terminal (1) from the generator.




62. If equipped with a automatic transaxle, disconnect the engine harness from the transaxle.




63. If equipped with a automatic transaxle, perform the following steps, disconnect the engine harness electrical connector (2) from the engine coolant temperature (ECT) sensor.
64. Remove the heater oxygen sensor (HO2S) connector position assurance (CPA) retainers.
65. Disconnect the engine harness electrical connectors (2, 4) from the heater oxygen sensors (HO2S).
66. Remove the HO2S connector clips from the thermostat housing and engine bracket.
67. Disconnect the engine harness electrical connector (1) from the park neutral position switch.




68. If equipped with a manual transaxle, disconnect the engine harness electrical connector (6) from the VSS.
69. Disconnect the engine harness electrical connector (7) from the back up lamp switch.
70. Remove the HO2S CPA retainers (2, 4).
71. Disconnect the engine harness electrical connectors (1, 5) from the HO2S.
72. Remove the HO2S clips from the engine brackets.
73. Gather all engine harness branches are reposition the harness off to the side, out of the way.




74. If equipped with a automatic transaxle, disconnect the range selector lever cable from the transaxle lever.
75. Remove the range selector lever cable from the transaxle bracket.




76. If equipped with a manual transaxle, disconnect the range selector and shift lever cables from the transaxle levers.
77. Remove the range selector and shift lever cables from the transaxle bracket.
78. Remove the catalytic converter.
79. Lower the vehicle.
80. Insert blocks of wood between the powertrain and the frame, in order to support the powertrain.
81. Remove the engine mount.




82. Remove the transaxle mount to transaxle bolts.
83. Raise the vehicle.
84. Disconnect the stabilizer links from the stabilizer bar.
85. Disconnect the outer tie rod ends from the steering knuckles.
86. Disconnect the intermediate shaft from the steering gear.
87. Disconnect the lower control arms from the steering knuckles.




88. Using a paint pen or magic marker, mark the frame to body position.
89. Lower the vehicle to about 3 feet off the ground.
90. Position a engine lift table under the frame.
91. Place wood blocks on top of the lift table between the table and the frame.
92. Lower the vehicle until the frame is resting on the blocks of wood.
93. Slowly loosen/remove the frame bolts using the following sequence:
1. Loosen/remove the front frame bolts.
2. Loosen/remove the rear frame bolts.
94. Slowly raise the vehicle away from the powertrain assembly.
95. Slide the lift table out from under the vehicle.
96. Attach the engine lift hoist to the engine lift hooks.




97. Remove the starter bolts and starter.




98. If equipped with a automatic transaxle, remove the torque converter housing access plug.




99. If equipped with a automatic transaxle, remove the torque converter bolts.




100. Remove the transaxle brace bolts and brace.




101. If equipped with a manual transaxle, remove the transaxle to engine bolts/stud.




102. If equipped with a automatic transaxle, remove the transaxle to engine bolts/stud.
103. Separate the engine from the transaxle.
104. If equipped with a manual transaxle, remove the clutch pressure plate and disc.
105. Remove the following components:
^ The engine mount bracket
^ The engine block heater
^ The generator
106. Using a engine hoist, install the engine to a engine stand.