Part 1

Engine Replacement

Tools Required

* J 38185 Hose Clamp Pliers
* J 37096 Flywheel Holding Tool
* J 45059 Angle Meter

Removal Procedure




1. Disconnect the negative battery cable.
2. Remove the hood.
3. Clean the area around the oil fill tube.
4. Twist the oil fill tube counterclockwise in order to unlock the tube from the valve rocker cover.
5. Lift the front of the manifold cover up and slide the tab out of the engine bracket.
6. Replace the oil fill tube into the valve rocker cover.
7. Raise and support the vehicle. Refer to Vehicle Lifting.




8. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement.
9. Drain the cooling system. Refer to Draining and Filling Cooling System (Static Fill) Draining and Filling Cooling System (Vac-N-Fill).
10. Remove the front transaxle converter cover bolt (1).
11. Remove the front transaxle converter cover (2).
12. Remove the rear transaxle converter cover bolts (3).
13. Remove the rear transaxle converter cover (4).
14. Remove the starter motor.




15. Remove the torque converter bolts. (engine shown removed for clarity).
16. Mark the relationship of the torque converter to the flywheel for installation.




17. Remove the transaxle brace to transaxle bolts.




18. Remove the transaxle brace to oil pan bolts and brace.




19. Remove the transaxle brace to transaxle bolts (1).




20. Remove the transaxle brace to engine and oil pan bolts and brace.




21. Remove the front engine mount to frame nut.




22. Remove the rear engine mount to frame nut.




23. Remove the exhaust manifold to catalytic converter nuts.




24. Disconnect the engine harness electrical connector (2) from the oil pressure sensor.
25. Disconnect the engine harness electrical connector (3) from the vehicle speed sensor (VSS).
26. Remove the engine harness clip (1) from the engine bracket.
27. Remove the engine harness clip (4) from the steering gear bracket.
28. Disconnect the engine harness electrical connector from the rear knock sensor jumper harness.




29. Disconnect the engine harness electrical connector (1) from the front knock sensor.
30. Disconnect the engine harness electrical connector (2) from the oil level sensor.
31. Remove the starter solenoid "S" terminal nut (4).
32. Remove the engine harness (3) terminal from the starter.
33. Disconnect the engine harness electrical connector (5) from the air conditioning (A/C) pressure sensor.
34. Disconnect the engine harness electrical connector (7) from the A/C compressor.




35. Remove the starter cable ground bolt (5) and reposition the starter cable terminal (2) from the engine.
36. Remove the starter "BAT" terminal nut (3).
37. Remove the starter cable terminal (4) from the starter.




38. Remove the right wheel drive shaft.
39. Remove the oil filter adapter bolts.
40. Remove the oil filter adapter and gasket.




41. Remove the lower rear transaxle bolt.




42. Remove the lower front transaxle bolt.
43. Lower the vehicle while supporting the transaxle.
44. Remove the air cleaner assembly.




45. Reposition the starter cable boot.
46. Remove the generator terminal nut.
47. Remove the starter cable from the generator.




48. Disconnect the fuel feed line (1) quick connect fitting from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service.
49. Disconnect the evaporative emission (EVAP) line (2) quick connect fitting from the purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service.




50. Loosen the water pump pulley bolts.
51. Remove the drive belt.
52. Remove the water pump pulley bolts and water pump pulley.
53. Remove the engine mount strut.
54. Remove the fan shroud.




55. Remove the brake booster vacuum hose from the intake manifold.




56. Remove the power steering pump bolts. Lay the power steering pump aside. (pulley shown removed for clarity).




57. Disconnect the engine harness electrical connectors (1) from the rear fuel injectors.
58. Remove the engine harness electrical connector retainers (2) from the fuel rail.




59. Disconnect the engine harness electrical connector from the rear heated oxygen sensor (HO2S).




60. Disconnect the engine harness electrical connector from the generator.




61. Disconnect the engine harness electrical connector (1) from the throttle actuator.
62. Disconnect the engine harness electrical connector (2) from the engine coolant temperature (ECT) sensor.




63. Disconnect the engine harness clips (1, 3) from the heat shield.
64. Disconnect the engine harness electrical connector (2) from the exhaust gas recirculation (EGR) valve.




65. Disconnect the engine harness electrical connectors (1) from the front fuel injectors.
66. Remove the engine harness retainers (2) from the fuel rail.




67. Disconnect the engine harness electrical connector (1) from the ignition control module harness electrical connector (2).
68. Disconnect the engine harness electrical connector (3) from the manifold absolute pressure (MAP) sensor.
69. Gather all branches of the engine wiring harness and reposition the harness out of the way.




70. Using J 38185 reposition the radiator inlet hose clamp at the thermostat housing.
71. Remove the radiator inlet hose from the thermostat housing.




72. Using J 38185 reposition the radiator outlet hose clamp at the front cover.
73. Remove the radiator outlet hose from the front cover.




74. Remove the heater inlet and outlet hose adapter bolts (1, 3). (heater hoses shown removed for clarity).
75. Remove the heater inlet (4) and outlet (2) adapters from the drive belt tensioner.





Important: It is not necessary to recover the A/C system.

76. Remove the A/C compressor bolts and nut. DO NOT discharge the A/C system.
77. Reposition and secure the A/C compressor to the frame.
78. Install a engine lifting device to the lift brackets.




79. Remove the upper transaxle bolts.
80. With the aid of an assistant, remove the engine from the vehicle.




81. Install the J 37096 to a ratchet.
82. Install the J 37096 and ratchet to the flywheel to hold the flywheel.




83. Loosen the flywheel bolts.
84. Remove 7 of the 8 flywheel bolts, leaving 1 bolt at the top of the crankshaft rotation.
85. Firmly grasp the flywheel and remove the remaining bolt. Do not drop the flywheel when removing the final bolt.
86. Remove the flywheel.
87. Install the engine to a engine stand.