Engine - Removal
REMOVAL
Special Tools:
CAUTION:
If the original engine has experienced a catastrophic failure or an individual failure with the piston, cylinder bore, engine block, valve or valve seat, the intake manifold MUST be replaced with a new manifold.
1. Perform the fuel pressure release procedure Service and Repair.
2. Disconnect and isolate the battery negative cable.
3. Drain the cooling system Service and Repair.
4. Evacuate the A/C system Service and Repair.
5. With the help of an assistant, remove the hood from the vehicle Hood - Removal.
NOTE: The engine cover is bonded to the air intake assembly. Do not attempt to separate them. The cover and intake must be removed as an assembly.
6. Loosen the air intake clamp (1) at the throttle body.
7. Disconnect the Intake Air Temperature (IAT) sensor (2).
8. Remove the breather tube (1) from the resonator (2).
9. Remove the air filter housing cover (2) and lower housing assembly (4).
10. Remove the cooling fan (3) Service and Repair.
11. Remove the upper intake manifold (2) and insulator Removal and Replacement.
12. Remove the two stud bolts (2) and remove the left rear upper intake manifold support bracket (1).
13. Remove the vacuum pump and bracket Removal.
14. Disconnect the fuel pressure sensor electrical connector (3).
15. Disconnect the fuel supply hose (2) at the in-line fuel pressure sensor Service and Repair.
16. Remove the accessory drive belt (1) Service and Repair.
17.
NOTE:
Mark and disconnect the left bank variable valve timing solenoid connectors (2) with a paint pen or equivalent so that they may be reinstalled in their original locations.
18. Remove the wire harness retainers (1) from the left cylinder head cover.
19. Disconnect the left side upstream O2 sensor wiring harness connector.
20. Mark and disconnect the right intake variable valve timing solenoid electrical connector (6).
21. Remove the wire harness retainers (1 and 3) from the right cylinder head cover.
22. Disconnect the right side upstream O2 sensor wiring harness connector.
23. Disconnect the field circuit connector (3) from the generator.
24. Remove the B+ terminal cable (2) from the generator stud.
25. Disconnect the main harness from the engine injection/ignition harness (1).
26. Disconnect three fuel injector electrical connectors (5).
27. Disconnect three ignition coil electrical connectors (2).
28. Disconnect the electrical connector (4) from the right Camshaft Position (CMP) sensor.
29. Remove the three main wire harness retainers (3) from the right cylinder head cover.
30. Disconnect the left Camshaft Position (CMP) sensor (5).
31. Remove the wire harness retainers (1, 2, and 4) from the cylinder head cover mounting stud.
32. Remove the ground straps (1) from the back of the cylinder heads.
33. Disconnect the ignition coil capacitor electrical connectors (2).
34. Disconnect the A/C compressor electrical connector.
35. Remove the A/C lines (2) at the condenser (1).
36. Remove the lower intermediate shaft coupler (1) at the steering gear (2).
37. Remove the A/C compressor (2).
38. Disconnect the power cord from the engine block heater (if equipped).
39. Partially raise the vehicle.
40. If required, drain the engine oil Service and Repair.
NOTE:
Right catalytic converter shown, left catalytic converter similar.
41. Remove the front wheels.
42. Remove the right and left upper catalytic converter bolts (2).
43. Disconnect the right and left side downstream oxygen sensor (1) connectors from the main wire harness.
44. Remove the bolts (1) that secure the coolant heater tubes to the cylinder head.
45. Remove the oil indicator (2).
46. Raise the vehicle.
NOTE: Right side catalytic converter flange shown. Left side similar.
47. Remove the left and right side catalytic converter to Y-pipe (1) flange nuts (2).
48. Remove the catalytic converters from the vehicle.
49. Loosen the catalytic converter flange bolts.
50. Remove the starter Service and Repair.
51. Remove the bolts (1) that secures the starter solenoid wiring harness (2) to the engine block, and position aside.
52. Slide the heat shield cover (1) from the temperature sensor (2).
53. Disconnect the Engine Coolant Temperature (ECT) sensor connector.
54. Remove the battery ground cable (1) from the engine block.
55. Disconnect the stop/start solenoid (1) electrical connector (4).
56. Remove the Battery positive cable (5) from the stop/start solenoid.
57. Rotate the crankshaft in a clockwise direction until the torque converter bolts (1) are accessible through the starter mounting.
58. Remove the main wire harness retainer (4) from the engine block.
59. Disconnect the oil pump solenoid electrical connector (1).
60. Remove the wire harness retainer (2) from the engine block.
61. Remove the wire harness retainer from the oil level indicator tube (1).
62. Remove the crankshaft positioning sensor electrical connector (3).
63. Remove the wire harness retainers from the engine block (2).
64. Remove the transmission cooler line retainer (1) from the oil pan flange.
65. Remove the bolt (2) that secures the thermal management lines (1) to the transmission bell housing.
66. Remove the transmission heater hose from the thermal management line.
67. Remove the bolt (2) and the torque converter dust shield (3).
68. Remove the side engine to transmission bolt (1).
69. If equipped with an automatic transmission;
- Remove two rubber plugs (1) covering the rear oil seal retainer flange bolts.
- Remove four transmission to the engine oil pan bolts (2 and 3).
70. Remove four upper transmission to engine bolts (1).
71. Remove the engine mount (6) heat shield (5).
72. Loosen the outer engine bracket bolt (4) from the engine bracket.
73. Remove the inner through engine bracket bolt (2).
74. 2WD vehicles, Loosen the engine support bolt (3).
75. Lower the vehicle.
76. Remove the upper radiator hose (1) from the engine thermostat housing and position aside.
77. Remove the heater line at the coolant crossover (1).
78. Remove the heater hose (1) at the water pump and position aside.
79. Remove the lower radiator hose (2) from the engine coolant pump housing and position aside.
80. Install the Driver Side Engine Lifting Bracket (10242-1) (1) on the LH cylinder head with bolts (2) provided with the Engine Lifting Bracket. Tighten the bolts to 21 Nm (15 ft. lbs.).
81. Install the Passenger Side Engine Lifting Bracket (10242-2) (1) on the RH cylinder head with bolts (2) from the Engine Lifting Bracket. Tighten the bolts to 21 Nm (15 ft. lbs.).
82. Reposition the main wire harness to the rear of the engine compartment.
Right engine mount shown, left engine mount similar.
83. Support the transmission with a suitable jack.
CAUTION:
While slowly separating the engine from the vehicle, constant checks must be made to assure proper positioning and that no damage to other components or wiring harnesses occur during separation.
84. Carefully remove the engine from the engine bay area.
85. If required, remove the following components for installation on the replacement engine:
- Lower intake manifold
- Start/Stop solenoid
- LH engine mount bracket
- RH engine mount bracket
- Accessory drive belt tensioner
- Generator
- Flywheel or flexplate
- Block heater (if equipped)