Removal Procedure
Engine Replacement- Tools Required
- J 37097-A Hose Clamp Remover/Installer
- J 38185 Hose Clamp Pliers
- J 39580 Universal Engine Support Table
- J42504 Engine Lift Bracket
Removal Procedure
1. Disconnect the battery negative cable.
2. Disconnect the battery positive cable from the battery and secure to the top of the engine.
3. Recover the A/C refrigerant system.
4. Disconnect the vacuum brake booster hose from the vacuum connection and position aside.
5. Disconnect the fuel inlet and return quick-connect fittings at the fuel rail and secure to the air inlet grille.
6. Disconnect the hose (4) from the evaporative emission canister purge valve (3) and secure behind the cruise control module.
7. Remove the radiator support sight shield.
8. Remove the air cleaner assembly.
9. Remove the two nuts (2) from the intake manifold sight shield (1).
10. Remove the sight shield (1) from the engine.
11. Disconnect and secure the following wiring harness electrical connectors to the top of the engine:
- The PCM.
- The C101 (1)
- The engine electrical harness.
12. Remove the nut securing the battery negative cable to the engine.
Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle. In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.
13. Push the lock release and remove the cruise control cable (2) from the throttle body bracket and lever (1).
14. Remove the accelerator control cable from the throttle body.
15. Remove the shift cable (2) from the bracket and manual shift lever (1) and position aside.
16. Drain the cooling system.
17. Position the J 37097-A to the clamp in order to remove the radiator inlet hose (1) from the water housing crossover and position aside.
18. Position the J 38185 to the clamp in order to remove the radiator outlet hose (2) from the thermostat housing and position aside.
19. Disconnect the surge tank inlet hose from the surge tank.
20. Disconnect the surge tank outlet hose from the heater pipe.
21. Disconnect the heater hoses from the heater pipes.
22. Remove the upper transaxle oil cooler pipe fitting from the radiator.
23. Remove the lower transaxle oil cooler pipe fitting from the radiator.
Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly.
24. Lock the steering column by removing the ignition key.
25. Remove the right and left side strut tower nuts.
26. Remove the engine mount struts.
27. Raise and support the vehicle. Refer to Vehicle Lifting.
28. Remove the rear exhaust manifold pipe.
29. Remove the front wheels.
30. Disconnect the front wheel speed sensor electrical connectors.
31. Disconnect the front wheel speed sensor electrical leads from the strut brackets.
32. Disconnect the following items (if equipped):
- The road sensing suspension electrical connector (3) from the main body harness.
- The road sensing suspension electrical leads (1) from the electronic suspension position sensor brackets.
- The road sensing suspension electrical leads (1) from the body frame rail retainer (4).
- The electronic suspension position sensor links (2) from the lower control arms.
33. Remove the engine slash shield.
34. Remove the front fascia extensions.
35. Remove the secondary AIR pump.
Caution: Brake fluid may irritate eyes and skin. In case of contact, take the following actions:
- Eye contact-rinse thoroughly with water.
- Skin contact-wash with soap and water.
- If ingested--consult a physician immediately.
36. Clean all dirt and foreign material from the brake hose and the brake pipe fittings.
37. Remove the front left brake pipe fitting from the brake hose.
38. Plug the open outlet ports to prevent fluid loss and contamination.
39. Use a flat-bladed tool in order to remove the front left brake hose retainer from the brake hose.
40. Remove the front left brake hose retainer from the brake hose retaining bracket.
41. Remove the bolt (2) securing the front right brake pipe frame bracket (1) to the body frame rail.
42. Disconnect the front right brake pipe from the retainer at the body frame rail.
43. Carefully pull the front right brake pipe away from the body frame rail.
Important: Record the location of the brake pipes to the Brake Pressure Modulator Valve (BPMV) for use as an aid during installation.
44. Remove the following brake pipes from the BPMV:
- The master cylinder brake pipes.
- The rear brake pipes.
- The left front brake pipe.
45. Plug the open outlet ports to prevent fluid loss and contamination.
46. Disconnect the A/C pressure sensor.
47. Disconnect the A/C discharge/suction hose (1) from the compressor (3) and secure to the bottom of the radiator assembly.
Caution: Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or damage to the intermediate shaft. This damage may cause loss of steering control which could result in personal injury.
Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly.
48. Remove the intermediate shaft pinch bolt.
49. Remove the steering gear from the intermediate shaft.
50. Disconnect the post H02S at the sensor pigtail.
51. Remove the engine oil cooler pipes from the engine oil filter adapter, and position aside (if equipped).
52. Remove the brace between the engine oil pan and the transaxle case.
53. Remove the torque converter cover.
Important: Mark the flywheel to torque converter relationship prior to removal of the bolts.
54. Remove the torque converter to the flywheel bolts.
55. Position the J 39580 powertrain support dolly under the engine frame.
56. Lower the vehicle on to the J 39580.
57. If the powertrain support dolly is unavailable. Support the powertrain with four suitable jackstands.
Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed.
58. Secure the front hoist pads to the vehicle.
59. Remove the six frame to body mounting bolts (3).
Important: Ensure clearance is maintained between the engine/transaxle assembly and the following:
- The A/C accumulator hose
- The A/C compressor hose
- The brake pipes
- The heater hoses
- The radiator hoses
- The wheel speed sensor leads
- The wiring harnesses
60. Carefully raise the vehicle in order to clear the supported engine/transaxle assembly.
61. Drain the engine oil.
62. Remove the heater pipes.
63. Disconnect the intermediate hose from the secondary AIR valve at bank 2.
64. Remove the nut securing the intermediate hose to the secondary AIR valve at bank 1.
65. Remove the bolt securing the secondary AIR pipe to the left engine mount strut bracket.
66. Remove the nut (3) securing the coil cassette ground wire to the right cylinder head.
67. Disconnect the engine wiring harness from the engine.
68. Remove the drive belt.
69. Disconnect the power steering return hose from the power steering pump reservoir.
70. Remove the power steering return hose retaining bolt from the right engine mount strut bracket.
71. Remove the power steering pressure hose (1) from the power steering pump (2).
72. Remove the power steering pressure hose (1) retaining bolt from the engine.
73. Remove the bolt securing the top of the generator to the right engine mount strut bracket.
74. Remove the three bolts securing the right engine mount strut bracket to the cylinder head.
75. Remove the right engine mount strut bracket from the engine.
76. Install the J 42504 to the cylinder head.
77. Install a engine lift chain to the engine lift brackets and attach to an engine lift devise.
78. Remove the two nuts (2) securing the right transaxle mount (1) to the engine frame.
79. Remove the three bolts securing the right transaxle mount (1) to the engine and transaxle.
80. Remove the right transaxle mount (1).
81. Remove the bolt (2) securing the rear transaxle brace (1) to the transaxle.
82. Remove the nuts (3) securing the rear transaxle brace (1) to the stud located on the right cylinder head.
83. Remove the rear transaxle brace (1).
84. Remove the nuts (2,3) securing the vehicle speed sensor heat shield (1) to the transaxle.
85. Remove the bolts securing the transaxle brace to the engine and transaxle.
86. Remove the two nuts (2) securing the front engine mount (2) to the engine frame.
87. Remove the bolts attaching the engine to the transaxle.
88. Raise the engine from the supported frame and transaxle assembly.
89. Remove the front engine mount.