Engine Removal

Engine Replacement

Tools Required
* J41798 Engine Lifting Brackets
* J21366 Converter Holding Strap
* J42371 Clutch Line Removal Tool
* J5824-01 Clutch Alignment Tool

Removal Procedure
1. Open the hood.
2. Place fender covers over both fenders.







3. Raise the hood to the service position, perform the following:
3.1. Remove the hood hinge bolts (1).
3.2. Raise the hood until vertical.
3.3. Install the hood hinge bolts until snug in the service position (2).

4. Remove the air conditioning (A/C) compressor.
5. Remove the radiator support.
6. Remove the engine sight shield.







7. Open the hose clamp and remove the radiate inlet hose from the water pump.







8. Open the hose clamp and remove the radiator outlet hose from the water pump.
9. Remove the heater hoses.







10. Disconnect the following electrical connectors:
- Evaporative Emissions (EVAP) canister purge solenoid (1)
- Generator (3)

11. Remove the harness bracket nut (2) in order to remove the engine harness from the intake manifold.







12. Reposition the vent inlet hose clamp at the throttle body.
13. Remove the radiator vent inlet hose from the throttle body.








14. Remove the generator cable from the generator, perform the following:
14.1. Slide the boot down revealing the terminal stud.
14.2. Remove the generator cable nut from the terminal stud.
14.3. Remove the generator cable.







15. Disconnect the main coil harness (2) and fuel injector electrical connectors on the left side.







16. Disconnect the following electrical connectors:
- Main coil harness (1)
- Fuel injectors (2)
- Electronic Throttle Control (ETC) (3)







17. Disconnect the Manifold Absolute Pressure (MAP) sensor (1) and knock sensor (2) electrical connectors.








18. Remove the harness ground bolt.
19. Reposition the harness ground and negative battery cable from the block.
20. Disconnect the following electrical connectors:
- Engine Coolant Temperature (ECT) sensor (1)
- Electronic variable orifice switch (2)







21. Remove the harness ground bolt at the right rear of the engine block.
22. Reposition the harness ground, and auxiliary negative battery cable, if equipped, from the block.
23. Remove the harness ground bolt at the left rear of the engine block.
24. Reposition the harness ground, and engine ground strap from the block.
25. Disconnect the following electrical connectors:
- Oil pressure sensor (1)
- Camshaft Position (CMP) sensor (2)


26. Unclip all of the engine harness clips from the engine.







27. Remove the battery cable junction block from the junction block bracket.







28. Remove the EVAP purge solenoid vent tube; perform the following:
- Remove the EVAP tube end from the solenoid (1).
- Remove the EVAP tube end from the vapor Pipe (2).

29. Disconnect the fuel pipes.
30. Raise the vehicle.







31. Disconnect the following electrical connectors:
- Crankshaft Position (CKP) sensor (1)
- Engine oil sensor (6)
- Coolant heater, if equipped.







32. Remove the battery cable channel bolt.
33. Slide the channel pin out of the oil pan tab.
34. Gather all branches of the engine wiring harness and reposition off to the side.
35. Lower the vehicle.






36. Remove the rear power steering to engine block bolt.
37. Remove the generator bracket bolts.
38. Position the bracket aside.







39. Remove the vacuum brake booster hose.
40. Remove the ignition coil(s) (as required) for the proper fit of the J41798 before lifting the engine.







Notice: Refer to Fastener Notice in Service Precautions.
Fastener Notice


41. Install the J41798 to the cylinder heads
- Tighten the M8 bolts to 25 Nm (18 ft. lbs.).
- Tighten the M10 bolts to 50 Nm (37 ft. lbs.).







42. Remove the left and right engine mount to engine mount bracket bolts.
43. Raise the vehicle.







44. Remove the engine sight shield bolts and shield.







45. Remove the oil pan skid plate bolts and plate, if equipped.
46. Drain the engine oil.
47. Remove the starter motor.
48. Remove the catalytic converter.







49. Remove the positive battery cable clip bolt and clip.







50. Remove the torque converter bolts, if equipped.







51. Remove the transmission oil level indicator tube nut, if equipped.







52. Remove the transmission oil level indicator tube, if equipped.







53. If equipped with a 4L60E transmission, remove the transmission bolt and stud on the right side.







54. If equipped with a 4L80E transmission, remove the transmission converter cover bolts.







55. Remove the automatic transmission bolt/studs, if equipped.
56. Separate the engine from the automatic transmission, if equipped. Install the J21366 to the transmission in order to hold the torque converter.







57. Using J42371 remove the clutch line form the concentric slave cylinder.







58. Remove the manual transmission stud on the right side of the transmission, if equipped.







59. Remove the manual transmission bolt/studs, if equipped.
60. Separate the manual transmission from the engine, if equipped.







61. Mark the flywheel and a clutch pressure plate lug for installation alignment.
62. Remove the clutch pressure plate bolts, if equipped.
63. Remove the clutch pressure plate and disc, if equipped.
64. Lower the vehicle.
65. Install an engine hoist to the J41798.
66. Install a floor jack under the transmission for support.

Notice: Use care while moving the engine assembly in order to avoid breaking the MAP sensor locating tabs. Broken MAP sensor tabs may result in decreased engine performance.

67. Remove the engine.
68. Install the engine to an engine stand.
69. Remove the engine hoist.







70. Remove the J41798 from the engine.