Removal Procedure

Engine Replacement
Removal Procedure





1. Ensure that the tires are in the straight forward position; remove the key from the ignition.
2. Raise the hood.
3. Disconnect the negative battery cable.
4. Remove the air cleaner assembly.
5. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
6. Disconnect the fuel feed line from the fuel rail.





7. Disconnect the evaporative emission (EVAP) line from the EVAP purge solenoid.





8. Drain the cooling system. Refer to Draining and Filling Cooling System (Static Fill) Draining and Filling Cooling System (GE 47716 Fill).
9. Secure the cooling module to the upper body structure.
10. Remove the engine drive belt.





11. Disconnect the cooling fan electrical connector.





12. Reposition the radiator inlet hose clamp at the engine.
13. Remove the radiator inlet hose from the engine.





14. Reposition the radiator outlet hose clamp (1) at the water outlet.
15. Reposition the radiator outlet hose clamp (2) at the oil cooler.
16. Remove the radiator outlet hose from the water outlet.
17. Remove the radiator outlet hose from the oil cooler





18. Reposition the heater inlet and outlet hose clamps at the thermostat housing.
19. Remove the heater inlet and outlet hoses from the thermostat housing.





20. Disconnect the engine coolant heater cord, if necessary.





21. Remove the engine coolant heater cord straps from the engine harness, if necessary.
22. Reposition the engine coolant heater cord out of the way, if necessary.





23. Reposition the brake booster vacuum hose clamp at the intake manifold.
24. Remove the brake booster vacuum hose from the intake manifold. Reposition the hose.





25. Disconnect the following electrical connectors:
^ Throttle actuator control (TAC) (1)
^ Manifold absolute pressure (MAP) sensor
^ Fuel injector harness (2)
^ Generator (3)





26. Disconnect the ignition coils electrical connectors (3).
27. Disconnect the intake (2) and exhaust (1) camshaft position actuator electrical connectors.





28. Remove the engine harness clips (1, 2) from the camshaft cover.





29. Remove the engine harness clip (1) from the oil level indicator tube bracket.
30. Remove the engine harness clips (2, 4) from the intake manifold.





31. If equipped with a automatic transaxle perform the following steps, remove the positive/negative battery cable ground nut (1).
32. Remove the positive/negative cable (2) terminal from the stud.
33. Remove the engine harness ground terminal (3) from the stud.
34. Disconnect the following electrical connectors:
^ Crankshaft position (CKP) Sensor (4)
^ Oil Pressure Sensor (5)
^ Knock Sensor (6)





35. If equipped with a manual transaxle perform the following steps, remove the positive/negative battery cable ground nut (2).
36. Remove the positive/negative cable (3) terminal from the stud.
37. Remove the engine harness ground terminal (4) from the stud.
38. Disconnect the following electrical connectors:
^ Crankshaft position (CKP) Sensor (1)
^ Oil Pressure Sensor (5)
^ Knock Sensor (6)





39. Disconnect the evaporative emission (EVAP) purge solenoid electrical connector (1).





40. Remove the engine harness clip (1) from the EVAP purge solenoid bracket.





41. Remove the engine harness clip nut (2).
42. Remove the engine harness clip (1) from the transaxle stud.





43. Disconnect the air conditioning (A/C) pressure switch electrical connector (1).
44. Disconnect the A/C compressor electrical connector (2).
45. Unbolt and reposition the AC compressor aside.
46. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.
47. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement.





48. Remove the engine harness clip nut (2) from the engine stud.
49. Remove the engine harness clip (1) from the stud.
50. If equipped with a automatic transaxle, disconnect the vehicle speed sensor (VSS) electrical connector (4).
51. Remove the engine harness clip (3) from the speed sensor.





52. If equipped with a automatic transaxle, perform the following steps, remove the positive/negative battery cable lead nut (4) from the starter solenoid.
53. Remove the positive battery cable (3) terminal from the starter.





54. If equipped with a manual transaxle, perform the following steps, remove the positive/negative battery cable lead nut (4) from the starter solenoid.
55. Remove the positive battery cable terminal (3) from the starter.





56. Remove the engine harness to starter solenoid "S" terminal nut (6).
57. Remove the engine harness lead terminal (5) from the starter solenoid.
58. Remove the engine harness ground bolt (7).
59. Remove the engine harness ground (8) from the engine block.
60. Lower the vehicle.
61. Reposition the engine harness boot (3).
62. Remove the generator nut (2).
63. Remove the engine harness lead terminal (1) from the generator.





64. If equipped with a automatic transaxle, disconnect the engine harness from the transaxle.





65. If equipped with a automatic transaxle, perform the following steps, disconnect the engine coolant temperature (ECT) sensor electrical connector (1).
66. Remove the connector position assurance (CPA) retainer (2).
67. Disconnect the engine harness electrical connector (3) from the heater oxygen sensor (HO2S).





68. If equipped with a manual transaxle, perform the following steps, disconnect the ECT sensor electrical connector (1).
69. Remove the CPA retainer (2).
70. Disconnect the engine harness electrical connector (3) from the HO2S.





71. If equipped with a automatic transaxle, perform the following steps, remove the CPA retainer (5).
72. Disconnect the engine harness electrical connector (6) from the neutral safety backup switch.
73. Remove the engine harness clip (1) from the transaxle stud.
74. Remove the CPA retainer (2).
75. Remove the engine harness electrical connector clip (4) from the transaxle rear mount bracket.
76. Disconnect the engine harness electrical connector (3) from the HO2S.





77. If equipped with a manual transaxle, disconnect the engine harness electrical connector (1) from the VSS.
78. Remove the engine harness clip (2) from the transaxle.
79. Remove the CPA retainer (3).
80. Remove the engine harness electrical connector clip (5) from the transaxle rear mount bracket.
81. Disconnect the engine harness electrical connector (4) from the HO2S.
82. Disconnect the engine harness electrical connector (7) from the back up lamp switch.
83. Remove the engine harness clip (6) from the transaxle.
84. Gather all engine harness branches are reposition the harness off to the side, out of the way.





85. If equipped with a automatic transaxle, disconnect the range selector lever cable from the transaxle lever.
86. Remove the range selector lever cable from the transaxle bracket.





87. If equipped with a manual transaxle, disconnect the range selector and shift lever cables from the transaxle levers.
88. Remove the range selector and shift lever cables from the transaxle bracket.
89. Remove the catalytic converter.
90. Remove the engine mount.





91. Remove the transaxle mount to transaxle bolts.
92. Raise the vehicle.
93. Disconnect the stabilizer links from the stabilizer bar.
94. Disconnect the outer tie rod ends from the steering knuckles.
95. Disconnect the intermediate shaft from the steering gear.
96. Disconnect the lower control arms from the steering knuckles.





97. Using a paint pen or magic marker, mark the frame to body position.
98. Lower the vehicle to about 3 feet off the ground.
99. Position a engine lift table under the frame.
100. Place wood blocks on top of the lift table between the table and the frame.
101. Lower the vehicle until the frame is resting on the blocks of wood.
102. Slowly loosen/remove the frame bolts using the following sequence:
1 Loosen/remove the front frame bolts.
2 Loosen/remove the rear frame bolts.
103. Slowly raise the vehicle away from the powertrain assembly.
104. Slide the lift table out from under the vehicle.
105. Attach the engine lift hoist to the engine lift hooks.





106. Remove the starter bolts and starter.





107. If equipped with a automatic transaxle, remove the torque converter housing access plug.





108. If equipped with a automatic transaxle, remove the torque converter bolts.





109. Remove the transaxle brace bolts and brace.





110. If equipped with a manual transaxle, remove the transaxle to engine bolts/stud.





111. If equipped with a automatic transaxle, remove the transaxle to engine bolts/stud.
112. Separate the engine from the transaxle.
113. If equipped with a manual transaxle, remove the clutch pressure plate and disc.
114. Remove the following components:
^ The engine mount bracket
^ The engine block heater
^ The generator
115. Using a engine hoist, install the engine to a engine stand.