Part 2
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
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. Refer to Oxygen Sensor Wiring Harness Heat Shield Replacement (Service and Repair) .
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 and strap the vehicle to the hoist.
79. Secure the front hoist pads to the vehicle.
80. Remove the front fascia. Refer to Front Bumper Fascia Replacement (Front Bumper Fascia Replacement) .
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
82. Carefully raise the vehicle in order to clear the supported engine/transaxle assembly.
83. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement (Service and Repair) .
84. Remove the heater outlet pipe nut (2) from the transaxle stud.
85. Reposition the heater outlet pipe clamp (1) at the water pump housing.
86. Remove the heater outlet pipe.
87. Remove the secondary air injection (AIR) inlet hose retainer from the transaxle stud.
88. Disconnect the AIR inlet hose quick connect fitting from the AIR pump. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service) .
89. Remove the AIR inlet hose.
90. Reposition the AIR outlet hose clamp at the AIR outlet pipe.
91. Separate the AIR outlet hose from the outlet pipe.
92. Remove the AIR pipe outlet pipe nut (3) from the transaxle stud.
93. Remove the AIR pipe outlet pipe nut (2) from the check valve bracket stud.
94. Disconnect the AIR outlet pipe quick connect fitting from the check valve. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service) .
95. Remove the AIR outlet pipe from the studs.
96. Remove the ignition control module (ICM) ground strap bolt (3) from the right cylinder head.
97. Remove the ICM ground strap (2) from the cylinder head.
98. 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)
99. 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)
100. Remove the engine harness clip (2) from the fuel rail stud.
101. Disconnect the following engine harness electrical connectors from the top of the engine:
* The starter inline (1)
* The AIR check valve (4)
102. Disconnect the engine harness electrical connector (1) from the engine valley jumper harness electrical connector.
103. Disconnect the engine harness electrical connector (3) from the power steering sensor.
104. Remove the engine harness clip (2) from the steering gear shield.
105. Remove the engine harness ground nut (4).
106. Remove the engine harness ground (5).
107. Disconnect the engine harness electrical connector (6) from the engine coolant temperature (ECT) sensor.
108. Disconnect the engine harness electrical connector (1) from the vehicle speed sensor (VSS).
109. Remove the engine harness clips (2, 3) from the rear engine mount bracket and steering gear shield.
110. Disconnect the engine harness electrical connector from the A/C pressure sensor.
111. Remove the engine harness clip (1) from the boss on the engine block.
112. 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)
113. Disconnect the engine harness electrical connectors from the following:
* The AIR pump (1)
* The brake modulator (2)
114. Remove the engine harness clip (1) from the engine bracket.
115. Remove the connector position assurance (CPA) retainer.
116. Disconnect the engine harness electrical connector (3) from the HO2S.
117. Disconnect the engine harness electrical connector from the transaxle.
118. Remove the engine harness ground bolts (2, 4, and 6).
119. Gather all the branches of the engine harness and remove the engine harness from the engine.
120. Reposition the power steering outlet hose clamp at the pump reservoir.