Engine, Removing
Engine, Removing
Notes:
- All tie wraps that are loosened or removed during engine removal must be replaced or reinstalled in the same positions when the engine is reinstalled.
- The engine is removed toward the front without the transmission.
- Drain coolant into a clean container for recycling or reuse.
CAUTION: Before disconnecting the battery, determine the correct coding for the anti-theft radio.
- Switch ignition off and disconnect battery Ground (GND) strap.
- Remove engine cover (arrows).
- Remove noise insulation panel (arrows).
- Remove front bumper. Service and Repair
- Unbolt cooling coil for power steering fluid (arrows) and let hang free. Do not open hydraulic fluid system.
- Open cap on coolant expansion tank.
WARNING: The cooling system is pressurized when the engine is warm. When opening the expansion tank, wear gloves and other appropriate protection, cover the cap with a cloth and open carefully to relieve system pressure slowly.
- Place VAG1306 drip tray underneath engine.
- Turn radiator drain plug counterclockwise (arrow); if needed, attach accessory hose to connection flange.
CAUTION: Dispose of used coolant properly.
- Open coolant pump housing drain plug as well (arrow).
Vehicles with air conditioning
CAUTION: The A/C refrigerant circuit must only be opened by specially trained technicians using the proper tools and equipment.
- DO NOT open the air conditioning refrigerant circuit.
- Disconnect A/C refrigerant line brackets and support points only.
- Set A/C compressor carefully aside. Avoid damage from bending. Refrigerant lines kink easily.
- Unbolt air ducts -4- at radiator on left and right sides.
- Unbolt retaining bolts -1- and -2- from condenser.
- Disconnect harness connector -3- at A/C refrigerant low pressure switch -F73-.
- Pull condenser upward out of retaining bracket, swing to side and hang at right-front wheel using wire loop.
All models
- Disconnect 5 harness connectors (arrows) located below trim cover in front of ABS hydraulic control module.
- Remove radiator hoses from radiator (top-left and bottom right).
- Remove bolts for air duct for air cleaner housing at front apron and lift air duct out.
- Remove lock carrier with attachments.
- Remove engine coolant expansion tank.
- Remove intake air hose between Mass Air Flow (MAF) sensor and intake air elbow.
- Disconnect Evaporative Emission (EVAP) canister purge regulator valve and remove valve from retainer.
- Disconnect harness connector for mass air flow sensor.
- Disconnect fuel supply and return lines.
WARNING:
- Fuel supply lines are under pressure! Before opening the system wrap a cloth around the connection. Then release pressure by carefully loosening connection.
- Fire hazard. Do not smoke, work near heaters or have anything in the area that could ignite the fuel or fumes.
- Turn air duct for Secondary Air Injection (AIR) pump 45° toward right (clockwise) and remove.
- Remove air cleaner housing.
- Remove wiper arms (arrows).
- Remove retaining clips -1- on water deflector.
- Remove left and right retaining clips -3- on water deflector.
- Remove water deflector.
- Remove cover -2- from Electronics Box (E-box).
- Disconnect retainer for Engine Control Module (ECM).
- Remove ECM, release harness connectors -3- and -4- and remove.
- Disconnect harness connectors from Barometric Pressure (BARO) sensor -F96- -1- and connector station -2-.
- Unhook wiring harness (arrow) and set aside.
- Disconnect ground connection -2- and remove harness connector bracket -1- at plenum chamber.
- Unhook wiring harness (arrow) and set aside.
- Remove both coolant hoses from heater core at engine by detaching clip at connection flange.
- Disconnect blue harness connector on Intake Manifold Tuning (IMT) valve; disconnect black harness connector for Intake Air Temperature (IAT) sensor on resonator.
- Cut tie wraps and move wiring to side.
- Disconnect vacuum line at cruise control vacuum diaphragm and at vacuum booster.
- Unbolt cruise control vacuum diaphragm; unhook cruise control vacuum diaphragm linkage at throttle body.
- Disconnect connections for EVAP leak detection system in engine compartment at tee (arrow).
- Disconnect hoses between vacuum booster and resonator.
- Disconnect harness connectors for camshaft adjustment valve and for fuel injectors (arrows).
- Disconnect wiring between EVAP canister purge regulator valve and throttle body at throttle body.
- Move disconnected hoses and wiring clear to one side.
- Remove resonator.
- Disconnect accelerator pedal cable from throttle valve control module -J338- and mounting flange without removing positioning clip. Lay accelerator pedal cable clear to side.
- Disconnect harness connectors on right side of plenum chamber and lay aside.
- Cut tie wrap on bracket for harness connectors.
- Pull lower parts of harness connector out of bracket and move wiring clear.
Vacuum line connections.
- Clamp off two hoses at hydraulic fluid supply line using 3094 hose clamps.
- Disconnect supply line (arrow) below left cylinder head.
- Place rag under connection to catch escaping fluid.
- Disconnect hydraulic pressure line at rear coolant line (left arrow).
- Disconnect hydraulic pressure line at right-side cylinder head (right arrow).
- Hold viscous fan pulley using 3212 spanner wrench and remove viscous fan using 3312 open-end spanner.
- To loosen ribbed belt, turn tensioner clockwise using 17 mm box wrench until two holes are aligned (arrows). Counterhold in position using 3204 drift.
CAUTION: Mark the running direction of the belt with a crayon or marker before removing. Reinstalling a used belt in reversed running direction could damage the belt.
- Remove ribbed belt.
- Unbolt air duct for generator from fan rib at lower left and disconnect from generator.
- Disconnect ground connection (engine/cross member) from engine (upper arrow).
- Open bracket (lower arrows) for wiring for starter and generator at longitudinal member.
- Disconnect cables from starter and generator and move cables clear.
- Unbolt generator and lay forward.
- Disconnect left and right-side exhaust pipes from exhaust manifold (arrows).
- Remove spring-loaded bolts on mounting brackets for Three Way Catalytic Converter (TWC).
- Move exhaust system toward rear and off studs on exhaust manifold.
- Disconnect starter and remove toward rear between subframe and drive axle.
Vehicles with automatic transmission
- Remove 3 bolts from torque converter (turn torque converter 1/3-turn (120°) each time).
- To remove engine, mount generator to bracket with one bolt.
Vehicles with air conditioning
CAUTION: The A/C refrigerant circuit must only be opened by specially trained technicians using the proper tools and equipment.
- DO NOT open the air conditioning refrigerant circuit.
- Disconnect A/C refrigerant line brackets and support points only.
- Set A/C compressor carefully aside. Avoid damage from bending. Refrigerant lines kink easily.
- Detach coolant and A/C refrigerant lines from oil pan at front of engine.
- Place VAG1306 drip tray underneath engine.
- Remove engine coolant lines below oil filter.
- Place oil drain pan below oil filter.
- Remove oil filter and oil cooler.
- Remove A/C compressor (with refrigerant hoses attached), swing toward right and hang up using wire.
All models
- Mark positions of mounts -1- and locating sleeves -2- on left and right-side engine mounts (bottom).
- Remove nuts -1- on left and right-side engine mounts.
Note: When installing, make sure that locating sleeves -2- engage again.
- Remove upper and lower engine/transmission bolts.
- Position 10-222A engine support bridge on bolted flanges of fenders.
- Engage 3147 engine support adapter in bolt hole in bellhousing on transmission and connect to spindle of 10-222A engine support bridge.
- Attach 2024A engine sling at right-rear and left-front and secure.
- Push engine crane into position and attach to engine sling.
WARNING:
- To properly balance the engine assembly, install the hooks in the correct hole in the rail, exactly as shown in the illustration.
- Install mounting hooks and pins on the engine sling and secure them with the positioning lock.
Note: Check to make sure that all of the hoses and connections between the engine and transmission have been disconnected.
- Carefully pull engine out toward front until free.
- Guide engine out of engine compartment from front.
Vehicles with automatic transmission
- Secure torque converter in transmission to prevent it from failing out.