Removal
Engine Replacement^ Tools Required
- J 37097-A Heater Hose Clamp Tool
- J 38185 Hose Clamp Pliers
- J 39580 Engine Support Stand
- J 41623-B Cooler Quick Connect Tool
- J 42504 Engine Lift Bracket
- J 42640 Steering Column Anti-Rotation Pin
Removal Procedure
1. Disconnect the battery negative cable.
2. Recover the A/C refrigerant system.
3. Disconnect the vacuum brake booster hose from the vacuum connection and position aside.
4. Disconnect the fuel inlet and return quick-connect fittings at the fuel rail and secure to the air inlet grille.
5. Disconnect the hose (4) from the evaporative emission canister purge valve (3) and secure to the air inlet grille.
6. Remove the upper filler panel.
7. Remove the air cleaner assembly.
8. Remove the 2 nuts (2) from the fuel injector sight shield (1).
9. Remove the fuel injector sight shield (1) from the engine.
10. Remove the nut (1) securing the battery positive cable to the remote positive terminal and secure to the top of the engine.
11. Disconnect the secondary AIR relay (1) from the relay bracket and secure to the top of the engine.
12. Disconnect and secure the following wiring harness electrical connectors to the top of the engine:
^ The PCM.
^ The C101 (1)
^ The engine electrical harness.
13. Remove the bolt (1) securing the engine ground cable (2) from the right side body frame rail.
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.
14. Push the lock release and remove the cruise control cable (2) from the throttle body bracket and lever (1).
15. Remove the accelerator control cable from the throttle body.
Push the lock release and remove the cruise control cable (2) from the throttle body bracket and lever (1).
16. Remove the shift cable (2) from the bracket and manual shift lever (1) and position aside.
17. Drain the cooling system.
18. 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.
19. Position the J38185to the clamp in order to remove the radiator outlet hose (2) from the thermostat housing and position aside.
20. Disconnect the surge tank inlet hose (1) from the water housing crossover.
21. Disconnect the surge tank outlet hose (3) from the heater pipe.
22. Disconnect the heater hoses (1, 2) from the heater pipes.
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.
Important: Record the location of the brake pipes to the brake pressure modulator valve (BPMV) for use as an aid during installation.
23. Remove the 2 master cylinder brake pipes (1) from the BPMV (2).
24. Plug the open outlet ports to prevent fluid loss and contamination.
25. Remove the upper transaxle oil cooler pipe retaining bolt from the fan shroud.
26. Slide the plastic cap off the upper transaxle oil cooler pipe quick connect fitting.
27. Disconnect the upper transaxle oil cooler pipe from the radiator using the J 41623-B.
28. Disconnect 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.
29. Lock the steering column by installing the J 42640 into underside of the steering column.
30. Remove the right and left side strut tower bolts.
31. Raise and support the vehicle.
32. Remove the rear exhaust manifold pipe.
33. Remove the front wheels.
34. Disconnect the front electronic brake pad wear sensor electrical connectors (1).
35. Disconnect the front electronic brake pad wear sensor electrical leads (3) from the strut brackets (6) and secure to the body frame rails (2).
36. Disconnect the front wheel speed sensor electrical leads (5) from the body frame rail (2).
37. Disconnect the road sensing suspension electrical connector at the body frame rail, if equipped.
38. Disconnect the road sensing suspension electrical leads (4) from the body frame rail (2), if equipped.
39. Disconnect the electronic suspension position sensor links (1) from the lower control arms, if equipped.
40. Remove the front air deflector.
41. Remove the front fascia extensions.
42. Disconnect the secondary AIR inlet hose from the secondary AIR pump.
43. Loosen the nuts (2) securing the front brake pipe frame brackets (1) to the body frame rails.
44. Disconnect the front brake pipes from the retainers at the body frame rails.
45. Carefully pull the front brake pipes away from the body frame rails.
46. Disconnect the 2 rear brake pipes at the rear of the engine frame.
Plug the open outlet ports to prevent fluid loss and contamination.
47. Disconnect the A/C pressure sensor.
48. Disconnect the A/C discharge hose from the compressor and secure to the cooling fan assembly.
49. Disconnect the A/C suction hose from the compressor and secure to the cooling fan 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.
50. Remove the intermediate shaft pinch bolt.
51. Remove the steering gear from the intermediate shaft.
52. Disconnect the post HO2S at the sensor pigtail.
53. Remove the engine oil cooler quick connect fittings from the engine oil filter adapter, with the oil pipes still attached, and position aside-if equipped.
54. Remove the brace between the engine oil pan and the transaxle case.
55. Remove the torque converter cover.
Important: Mark the flywheel to torque converter relationship prior to removal of the bolts.
56. Remove the torque converter to the flywheel bolts.
57. Position the J 39580 powertrain support dolly under the engine frame.
58. Lower the vehicle on to the J 39580.
59. If the powertrain support dolly is unavailable, support the powertrain with 4 suitable jackstands.
60. Place a 2 in x 4 in block of wood between the front of the engine oil pan and the engine frame.
61. Remove the nut securing the right engine mount to the right engine mount bracket.
62. Remove the nut (1) securing the left transaxle mount to the left transaxle mount bracket.
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.
63. Secure the front hoist pads to the vehicle.
64. Remove the 6 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 electronic brake pad wear sensor leads
^ The heater hoses
^ The radiator hoses
^ The wheel speed sensor leads
^ The wiring harnesses
65. Carefully raise the vehicle in order to clear the supported engine/transaxle assembly.
66. Drain the engine oil.
67. Remove the heater pipes.
68. Disconnect the intermediate hose from the secondary AIR valve at bank 2.
69. Remove the nut securing the intermediate hose to the secondary AIR valve at bank 1.
70. Remove the nut (3) securing the coil cassette ground wire to the right cylinder head.
71. Disconnect the engine wiring harness from the engine.
72. Disconnect the power steering hose from the power steering pump reservoir.
73. Remove the power steering return hose retaining bolt from the cylinder head.
74. Remove the power steering pressure hose from the power steering pump.
75. Remove the nut (2) securing the power steering pressure hose to the right engine mount bracket (1).
76. Remove the 4 bolts securing the right engine mount bracket (1) to the engine.
77. Remove the right engine mount bracket (1).
78. Remove the bolt (2) securing the rear transaxle brace (1) to the transaxle.
79. Remove the nuts (3) securing the rear transaxle brace (1) to the stud located on the right cylinder head.
80. Remove the rear transaxle brace (1).
81. Remove the bolts (1, 3) securing the front transaxle brace (2) to the transaxle and right cylinder head.
82. Remove the nuts (2, 3) securing the vehicle speed sensor heat shield (1) to the transaxle.
83. Remove the bolts securing the center transaxle brace to the engine and transaxle.
84. Install the J 42504 to the cylinder head.
85. Install a engine lift chain to the engine lift brackets and attach to an engine lift devise.
86. Remove the nut securing the front engine mount 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 bracket.