Part 1

Engine Replacement

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

Removal Procedure




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (with CH 48027-100) (Fuel Pressure Relief (with CH 48027-100))Fuel Pressure Relief (without CH 48027-100) (Fuel Pressure Relief (without CH 48027-100)).
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
3. Disconnect the fuel feed pipe (1) quick connect fitting at the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (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 (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, and LE5) ()Battery Tray Replacement (LAT) ().
8. LAT only, 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 (LE5) (Service and Repair)Radiator Outlet Hose Replacement (LAT) (Service and Repair)Radiator Outlet Hose Replacement (LY7) (Service and Repair).




17. LAT only, reposition the generator control module coolant hose clamp (1) at the generator control module.
18. LAT only, remove the generator control module coolant hose from the generator control module.




19. LAT only, 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 (Service and Repair).
25. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement (Service and Repair).




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




28. LAT only, 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. LE5 only:

1. Disconnect the generator electrical connector (1).
2. Reposition the engine harness boot (3).
3. Remove the generator nut (2).
4. Remove the engine harness lead (4) from the generator.




34. LAT only, disconnect the engine wiring harness electrical connector (2) from the auxiliary heater water pump.




35. LAT only, remove the auxiliary heater water pump bolt and pump.
36. Lower the vehicle.




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





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

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




40. Raise the vehicle.
41. Remove the front wheels and tires. Refer to Tire and Wheel Removal and Installation (Service and Repair).
42. Remove the front wheelhouse panel. Refer to Front Wheelhouse Panel Splash Shield Replacement (Service and Repair).

Note: A piece of hardwood should be used between the transaxle and the frame. This wood will support the engine when the left side engine mounts bolts are removed.

43. Install a piece of hardwood 1 x 2 x 4 between the transaxle and the frame.

Note: A piece of hardwood should be used between the oil pan and the frame. This wood will support the engine when the right side engine mounts are removed.

44. Install a piece of hardwood 1 x 2 x 4 between the oil pan and the frame.




45. Drain the transaxle fluid.
46. If equipped with the 4T45, remove the transaxle oil cooler line to transaxle nut (1).
47. If equipped with the 4T45, remove the transaxle oil cooler lines from the transaxle.
48. If equipped with the 6T40, remove the fluid cooler lines at the transmission. Refer to Fluid Cooler Inlet Hose Replacement (Service and Repair) and Fluid Cooler Outlet Hose Replacement (Service and Repair).
49. Remove the catalytic converter. Refer to Exhaust Manifold Pipe Replacement (LE5) (Service and Repair).





Note: Secure the steering wheel in the straight forward position before separating the intermediate shaft from the steering gear, or damage to the SIR coil will occur.

50. Remove the intermediate to steering gear pinch bolt and disconnect the intermediate shaft from the steering gear. Discard the pinch bolt.




51. Remove and discard both outer tie rod to steering knuckle nuts.

Note: Hold the ball stud to prevent turning during removal of the nut.

52. Separate the tie rods from the steering knuckles. Refer to Steering Linkage Outer Tie Rod Replacement (Steering Linkage Outer Tie Rod Replacement).




53. Remove the stabilizer link to stabilizer shaft nuts and disconnect the stabilizer links from the stabilizer shaft.




54. Remove and discard both of the lower control arm ball stud cotter pins.
55. Loosen the ball stud nuts until the nuts are level with the top of the ball stud.




56. Using the J 43828 , separate the lower control arms from the steering knuckles.
57. Remove the ball stud nuts.
58. Remove the wheel drive shafts. Refer to Wheel Drive Shaft Replacement (Wheel Drive Shaft Replacement).
59. Lower the vehicle.




60. Remove the engine mount to bracket bolts (1).




61. Remove the transaxle mount to transaxle bolts.
62. Raise the vehicle.





Note: During the powertrain removal support the vehicle body by placing a jack at the rear of the vehicle.

63. Position a engine support table under the powertrain assembly.

Note: Blocks of wood can be used between the front of the frame and the oil pan to table in order to level the powertrain during the removal.

64. With the table positioned, fully raise the table to contact with the powertrain assembly.
65. Remove the frame to body bolts. Discard the bolts.

Note: When lowering the engine/transaxle assembly, verify all brake lines, shifter cables and other components are free during removal.

66. Lower the engine table and raise the body on the hoist until the engine/transaxle and frame are free from the vehicle.




67. Disconnect the engine wiring harness electrical connector (1) from the throttle actuator.
68. Disconnect the engine wiring harness electrical connector (8) from the fuel injector wiring harness electrical connector (7).
69. Remove the engine wiring harness clip (3) from the oil level indicator tube bracket.




70. Disconnect the engine wiring harness electrical connectors (1) from the ignition coils.
71. Disconnect the engine wiring harness electrical connectors (2, 3) from the camshaft actuators.




72. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor.
73. Disconnect the engine wiring harness electrical connector (2) from the oil pressure sensor.
74. Disconnect the engine wiring harness electrical connector (3) from the knock sensor.




75. Disconnect the engine wiring harness electrical connector (1) from the intake camshaft position (CMP) sensor.
76. Disconnect the engine wiring harness electrical connector (2) from the EVAP emission canister purge solenoid valve.




77. Disconnect the engine wiring harness electrical connector (1) from the exhaust CMP sensor.




78. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor.
79. Disconnect the engine wiring harness electrical connector (3) from the heated oxygen sensor (HO2S) electrical connector.
80. Remove the engine wiring harness clip (5) from the stud.




81. Remove the engine wiring harness ground bolt (1) and reposition the ground terminal from the engine.
82. Gather all branches of the engine wiring harness and reposition the harness out of the way.




83. Remove the starter motor bolts and starter.




84. Remove the torque converter to flexplate bolts (1).
85. Install a suitable lifting devise to the engine.




86. If equipped with the 4T40, remove the transaxle bolts from the engine.




87. If equipped with the 6T40, remove the transaxle bolts (1, 2, 3, 4) from the engine.
88. If equipped with the 6T40, remove the intermediate drive shaft. Refer to Wheel Drive Shaft Replacement (Wheel Drive Shaft Replacement).
89. Separate the engine from the transaxle.
90. Install the engine to a suitable engine stand.