Part 1

Engine Replacement


Special Tools
* J 38185 Hose Clamp Pliers
* J 43828 Ball Joint Remover
* J 44015 Steering Linkage Installer
* J 44015 Tie Rod Installer



Removal Procedure





1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027-100) Fuel Pressure Relief (Without CH 48027-100) .
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (1st Design) Air Cleaner Assembly Replacement (2nd Design) .
3. Disconnect the fuel feed pipe (1) quick connect fitting at the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
4. Disconnect the evaporative emission (EVAP) line (3) quick connect fitting from the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service .
5. Remove the fuel feed pipe clip (2) from the fuel line bracket.




6. Remove the transaxle shift cable clip (1) from the fuel line bracket.
7. Remove the battery tray. Refer to Battery Tray Replacement (LZ4/LY7) Battery Tray Replacement (LAT) .
8. Remove the generator starter. Refer to Generator with Starter Replacement .




9. Reposition the vacuum brake booster hose clamp (1) at the intake manifold.
10. Remove the vacuum brake booster hose (2) from the intake manifold. Reposition the brake booster hose out of the way.




11. Remove the coolant recovery inlet hose clamp (2) at the cylinder head.
12. Remove the coolant recovery inlet pipe clip from the fuel rail.
13. Remove the coolant recovery inlet hose (1) from the cylinder head. Reposition the hose/pipe out of the way.




14. Reposition the radiator inlet hose clamp using the J 38185 .
15. Remove the radiator inlet hose from the cylinder head.
16. Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (LAT) (Service and Repair)Radiator Outlet Hose Replacement (LE5) (Service and Repair)Radiator Outlet Hose Replacement (LY7) Radiator Outlet Hose Replacement (LZ4) (Service and Repair) .




17. Reposition the generator control module coolant hose clamp (1) at the generator control module.
18. Remove the generator control module coolant hose from the generator control module.




19. Disconnect the engine wiring harness electrical connector (1) from the transaxle auxiliary pump module.




20. Reposition the heater inlet hose clamp (1) at the thermostat housing.
21. Remove the heater inlet hose (2) from the thermostat housing.
22. Reposition the coolant recovery reservoir/heater inlet hose (3) clamp at the thermostat housing.
23. Remove the coolant recovery reservoir/heater inlet hose (4) from the thermostat housing.
24. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
25. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement (Service and Repair) .




26. Disconnect the engine wiring harness electrical connector (1) from the generator control module coolant pump.
27. Disconnect the engine wiring harness electrical connector (2) from the air conditioning (A/C) compressor.




28. Remove the generator control module coolant pump bolt (3) and pump (2).




29. Unbolt the A/C compressor and reposition out of the way.




30. Remove the positive battery cable to starter motor nut (4).
31. Remove the positive battery cable lead (1) from the starter motor.
32. Remove the positive battery cable from in between the starter and the engine. Reposition the positive battery cable out of the way.




33. Disconnect the engine wiring harness electrical connector (2) from the auxiliary heater water pump.




34. Remove the auxiliary heater water pump bolt and pump.
35. Lower the vehicle.




36. Remove the transaxle shift cable from the range select lever.
37. Release the shift control cable retaining clip and remove the cable from the shift control cable bracket.





Important: The radiator/condenser/fan assembly will stay in the vehicle during engine removal.


38. Using long tie straps, secure the radiator/condenser/fan assembly to the radiator support.




39. Raise the vehicle.