Part 1

Engine Replacement

Tools Required
* J 37097-A Hose Clamp Remover/Installer
* J 38185 Hose Clamp Pliers
* J 39580 Universal Engine Support Table
* J 41623-B Cooler Quick Connect Tool
* J 42640 Steering Column Lock Pin

Removal Procedure




1. Disconnect the negative battery cable.
2. Remove the fuel injector sight shield.
3. Recover the air conditioning (A/C) refrigerant system. Refer to Refrigerant Recovery and Recharging.
4. Reposition the brake booster vacuum hose clamp at the engine port.
5. Disconnect the brake booster vacuum hose from the vacuum connection and position aside.




6. Disconnect the fuel feed and evaporative emission (EVAP) line quick-connect fittings (1, 2).
7. Remove the front compartment sight shield.
8. Remove the air cleaner.




9. Disengage the junction block cover lock tabs.
10. Remove the junction block cover.




11. Remove the nut (1) securing the starter cable to the bussed electrical center (BEC).
12. Remove the starter cable clip (4) from the BEC.
13. Remove the starter cable from the BEC terminal and secure to the top of the engine.




14. Disengage the lever lock.
15. Disconnect the engine harness electrical connector from the transaxle control module (TCM).




16. Disengage the lever lock.
17. Disconnect the engine harness electrical connector from the body harness electrical connector.
18. Secure the TCM and engine harness wiring branches to the engine.




19. Disengage the lever locks.
20. Disconnect the engine harness electrical connectors from the engine control module (ECM).




21. Remove the junction block bolts.
22. Remove the junction block.




23. Remove the engine harness (1) from the BEC.




24. Remove the engine ground strap bolt (1) from the right side frame rail.
25. Secure the ground strap to the engine.




26. Remove the transaxle shift cable clip from the shift cable bracket.




27. Remove the transaxle shift cable retainer (1).




28. Disconnect the transaxle shift cable end (2) from the range selector lever (1).
29. Remove the transaxle shift cable from the bracket and position the cable aside.
30. Drain the cooling system.




31. Using the J 37097-A reposition the radiator inlet hose clamp (1).
32. Remove the radiator inlet hose (2) from the water pump housing and position aside.




33. Using the J 38185 reposition the radiator outlet hose clamp (1).
34. Remove the radiator outlet hose (2) from the thermostat housing and position aside.




35. Reposition the radiator surge tank inlet hose clamp at the surge tank.
36. Remove the surge tank inlet hose from the surge tank.




37. Reposition the heater inlet (1) and outlet (2) hose clamps at the heater pipes.
38. Remove the heater inlet (2) and outlet (3) hoses from the heater pipes.




39. Remove the master cylinder nuts and master cylinder from the brake booster.
40. Reposition the master cylinder and secure the master cylinder to the engine.




41. Loosen the upper transaxle oil cooler pipe bolt (1) from the fan shroud.
42. Slide the plastic caps off the transaxle oil cooler pipe quick connect fittings.
43. Remove the right front engine mount strut bolt.
44. Disconnect the transaxle oil cooler pipes from the radiator using the J 41623-B.





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.

45. Lock the steering column by installing the J 42640 into the underside of the steering column.




46. Remove the left and right side strut tower bolts (1). (Left side shown, right side similar.)
47. Raise and support the vehicle. Refer to Vehicle Lifting.
48. Remove the rear exhaust manifold pipe.
49. Remove the front wheels.




50. Remove the engine harness grommet (2) from the frame rail bracket.
51. Remove the engine harness clip (3) from the ride lever sensor bracket.




52. Disconnect the electronic suspension front position sensor link from the lower control arms ball stud, if equipped.




53. Loosen the nut (2) securing the left front brake pipe bracket (4) to the body frame rail.
54. Remove the front brake pipe bracket (4) from the body frame rail.




55. Loosen the nut (1) securing the right front brake pipe bracket (4) to the body frame rail.
56. Remove the front brake pipe bracket (4) from the body frame rail.




57. Disconnect the rear brake pipes from the front brake pipes.
58. Plug the open brake lines in order to prevent fluid loss and/or system contamination.




59. Remove the A/C compressor discharge hose bolt at the condenser.
60. Remove the A/C compressor discharge hose from the condenser and secure to the engine.
61. Plug the A/C condenser discharge port.




62. Remove the A/C compressor suction hose nut at the condenser.
63. Remove the A/C compressor suction hose from the condenser and secure to the engine.
64. Plug the A/C condenser suction port.





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.

65. Remove the intermediate steering shaft cover.
66. Remove the intermediate shaft pinch bolt.
67. Remove the intermediate shaft from the steering gear.




68. Remove the oxygen sensor wiring harness heat shield.
69. Disconnect the engine harness electrical connector from the heated oxygen sensor (HO2S).




70. Remove the transaxle brace bolts.
71. Remove the transaxle brace.




72. Remove the torque converter cover bolt.
73. Remove the torque converter cover.





Important: Mark the flywheel to torque converter relationship prior to removal of the bolts.

74. Remove the flywheel to torque converter bolts. (Engine removed for clarity).




75. Position the J 39580 under the frame.
76. Lower the vehicle onto the J 39580.




77. If the J 39580 is not available. Support the powertrain with four suitable jackstands.
78. Place a 2 in x 4 in block of wood between the front of the engine oil pan and the engine frame.

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.

79. Secure the front hoist pads to the vehicle.
80. Remove the front fascia.




81. Remove the 6 bolts (1) attaching the frame to the body. (Left side shown, right side similar).

Important: Ensure clearance is maintained between the engine/transaxle assembly and the following:

* The A/C compressor components

* The brake pipes

* The heater hoses

* The radiator hoses

* The wheel speed sensor leads

* The wiring harnesses

Carefully raise the vehicle in order to clear the supported engine/transaxle assembly.
82. Drain the engine oil.




83. Remove the heater outlet pipe nut (2) from the transaxle stud.
84. Reposition the heater outlet pipe clamp (1) at the water pump housing.
85. Remove the heater outlet pipe.




86. Remove the secondary air injection (AIR) inlet hose retainer from the transaxle stud.
87. Disconnect the AIR inlet hose quick connect fitting from the AIR pump.
88. Remove the AIR inlet hose.




89. Reposition the AIR outlet hose clamp at the AIR outlet pipe.
90. Separate the AIR outlet hose from the outlet pipe.




91. Remove the AIR pipe outlet pipe nut (3) from the transaxle stud.
92. Remove the AIR pipe outlet pipe nut (2) from the check valve bracket stud.
93. Disconnect the AIR outlet pipe quick connect fitting from the check valve.
94. Remove the AIR outlet pipe from the studs.




95. Remove the ignition control module (ICM) ground strap bolt (3) from the right cylinder head.
96. Remove the ICM ground strap (2) from the cylinder head.




97. Disconnect the following engine harness electrical connectors from the rear of the engine:

* The EVAP solenoid (1)
* The exhaust gas recirculation (EGR) valve (2)
* The fuel injectors (3)
* The ICM (4)




98. Disconnect the following engine harness electrical connectors from the front of the engine:

* The fuel injectors (1)
* The ICM (3)
* The manifold absolute pressure (MAP) sensor (4)
* the throttle actuator (5)

99. Remove the engine harness clip (2) from the fuel rail stud.




100. Disconnect the following engine harness electrical connectors from the top of the engine:

* The starter inline (1)
* The AIR check valve (4)




101. Disconnect the engine harness electrical connector (1) from the engine valley jumper harness electrical connector.




102. Disconnect the engine harness electrical connector (3) from the power steering sensor.
103. Remove the engine harness clip (2) from the steering gear shield.
104. Remove the engine harness ground nut (4).
105. Remove the engine harness ground (5).
106. Disconnect the engine harness electrical connector (6) from the engine coolant temperature (ECT) sensor.




107. Disconnect the engine harness electrical connector (1) from the vehicle speed sensor (VSS).
108. Remove the engine harness clips (2, 3) from the rear engine mount bracket and steering gear shield.




109. Disconnect the engine harness electrical connector from the A/C pressure sensor.




110. Remove the engine harness clip (1) from the boss on the engine block.
111. Disconnect the following engine harness electrical connectors:

* The oil pressure sensor (2)
* The oil level sensor (3)
* The A/C compressor (4)
* The generator (5)




112. Disconnect the engine harness electrical connectors from the following:

* The AIR pump (1)
* The brake modulator (2)




113. Remove the engine harness clip (1) from the engine bracket.
114. Remove the connector position assurance (CPA) retainer.
115. Disconnect the engine harness electrical connector (3) from the HO2S.




116. Disconnect the engine harness electrical connector from the transaxle.
117. Remove the engine harness ground bolts (2, 4, and 6).
118. Gather all the branches of the engine harness and remove the engine harness from the engine.




119. Reposition the power steering outlet hose clamp at the pump reservoir.
120. Remove the power steering outlet hose from the reservoir.
121. Remove the power steering outlet pipe bolt from the engine mount strut bracket.




122. Remove the power steering inlet pipe fitting from the power steering pump.
123. Remove the power steering inlet pipe nut (1) from the rear engine mount bracket stud.
124. Remove the power steering inlet pipe bracket from the stud.




125. Remove the A/C compressor discharge hose nut at the compressor.
126. Unsecure the hose from the engine and remove the A/C compressor discharge hose.
127. Plug the A/C compressor discharge port.




128. Remove the A/C compressor suction hose nut at the compressor.
129. Unsecure the hose from the engine and remove the A/C compressor suction hose.
130. Plug the A/C compressor suction port.




131. Remove the transaxle brace bolt.
132. Remove the transaxle brace nuts.
133. Remove the transaxle brace.




134. Remove the transaxle brace bolt/stud to the transaxle.




135. Remove the transaxle brace bolts to the engine.
136. Remove the transaxle brace.




137. Loosen the front engine mount bracket nut with the transaxle brace behind it.




138. Remove the transaxle brace bolt.
139. Remove the transaxle brace.




140. Install an engine lift chain to the engine lift brackets and attach an engine lifting device.
141. Remove the rear engine mount to frame nut.




142. Remove the rear engine mount bracket bolts and stud.
143. Remove the rear engine mount bracket.




144. Remove the front engine mount to frame nut.




145. Remove the rear transaxle bolt.




146. Remove the upper transaxle bolts.
147. Separate the engine from the transaxle.
148. Raise the engine from the supported frame and transaxle assembly.




149. Remove the front engine mount bracket bolts/nuts.
150. Remove the front engine mount bracket.
151. Install the engine assembly to a suitable engine stand.