Engine Removal

Engine Removal

NOTE:
^ Use fender covers to avoid damaging painted surfaces.
^ To avoid damaging the wire and terminals, 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 customer's audio presets.
3. Relieve fuel pressure.
4. Disconnect the negative cable from the battery first, then disconnect the positive cable.
5. Remove the battery.





6. Remove the intake manifold cover.





7. Disconnect the intake air temperature (IAT) sensor connector (A), and remove the breather hose (B), then remove the air cleaner housing (C).





8. Remove the air intake duct.





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





10. K20A3 engine: 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 actuator cable (C) from the links. Loosen the locknuts (D), and remove the cables from the bracket,





11. K20A2, K20Z1 engines: Fully open the throttle link and cruise control link by hand, then remove the throttle cable (A) and cruise control actuator cable (B) from the links. Loosen the locknuts (C), and remove the cables from the bracket.





12. Disconnect the engine control module (ECM)/Powertrain control module (PCM) connectors (A) and main wire harness connector (B).





13. Remove the harness clamps (A) and grommet (B), then pull the engine wire harness through the bulkhead.
14. Remove the fuel feed line.





15. Remove the evaporative emission (EVAP) canister hose (A) and brake booster vacuum hose (B).





16. Remove the clutch slave cylinder (A) and clutch line bracket mounting bolt (B) (M/T).





17. Remove the shift cable (A) and select cable (B) (M/T).
18. Remove the drive belt.





19. Remove the power steering (P/S) pump without disconnecting the P/S hoses.





20. Remove the bolt securing the P/S hose bracket.
21. Remove the radiator cap.
22. Raise the vehicle on the hoist to full height.
23. Remove the front wheels.





24. Remove the splash shield.
25. Loosen the drain plug in the radiator, and drain the engine coolant.
26. Drain the transmission fluid.
27. Drain the engine oil.





28. Disconnect the air fuel ratio (A/F) sensor connector (A) and secondary heated oxygen sensor (secondary HO2S) connector (B).
29. Remove the three way catalytic converter (TWC) assembly (C).
30. 2005-2006 models: Check the flexible joint gasket (D) for damage. If the flexible joint gasket is damaged, replace the flexible joint gasket.

NOTE: Do not reuse the flexible joint gasket, when removing it.

31. Disconnect the suspension lower arm ball joints and the stabilizer links.
32. Remove the driveshafts. Coat all precision finished surfaces with clean engine oil. Tie plastic bags over the driveshaft ends.





33. Remove the shift cable holder (A), then remove the shift cable cover (B). To prevent damage to the control lever joint, be sure to remove the bolts securing the shift cable cover (A/T).
34. Remove the spring clip (C) and control pin (D), then separate the shift cable (E) from the control lever (F) (A/T).





35. Remove the lower hose.





36. Remove the automatic transmission fluid (ATF) filter mounting bolt (A) (A/T).
37. Remove the ATF cooler hoses (B), then plug the ATF cooler hoses and lines (A/T).
38. Lower the vehicle on the hoist.





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





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








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





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








45. Remove the rear mount mounting bolts.





46. Remove the front mount bracket mounting bolt.





47. Use a marker to make alignment marks on the reference lines (A) that align with the centers of the rear subframe mounting bolts (B).
48. Remove the front subframe (C).





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