Operation CHARM: Car repair manuals for everyone.

Part 1

Engine

Special Tool(s):




Material:





Removal (Steps 1-36)
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
2. Disconnect the battery ground cable. For additional information, refer to Battery.
3. Remove the A/C condenser assembly. For additional information, refer to Heating and Air Conditioning.
4. Remove the front bumper.
5. Remove the radiator grille support.
6. Remove the intake manifold.
7. Remove the bolts, disconnect and remove the air bag sensor. Position the headlamp wiring harness aside.





8. NOTE: Mark the latch before removal.

Remove the 2 bolts and hood latch.





9. NOTE: RH shown, LH similar.

Remove the 8 bolts and the upper radiator support.





10. NOTE: LH shown, RH similar.

Remove the 12 bolts and lower radiator support.





11. Remove the RH fan stator stand-off. Remove the bolt and position the cable aside.





12. Disconnect the A/C electrical connector.





13. Disconnect the A/C pressure switch and remove the A/C manifold from the tee block.
^ Remove and discard the O-ring seals.
^ Cap or plug the A/C openings as needed.





14. Remove the bolts and A/C compressor.





15. Disconnect the heater hose and position the heater hose and tube aside.





16. Remove the bolt and idler pulley.





17. NOTE: The nut behind the pulley is accessed through one of the holes in the pulley.

Remove the nuts and the coolant hose shield.





18. Loosen the clamp and disconnect the engine coolant fill hose.





19. Disconnect the vacuum pump hose.





20. NOTE: The stud bolt behind the pulley is accessed through one of the holes in the pulley.

Remove the stud bolts and the vacuum pump.





21. Remove the power steering upper mounting bolts.





22. Remove the LH fan stator stand-off.





23. NOTE: The front bolt will remain in the power steering pump.

Remove the 2 bolts and position the power steering pump aside.





24. Remove the lower radiator hose.





25. Disconnect the fuel tube spring lock couplings. For additional information, refer to Fuel Delivery and Air Induction.





26. Disconnect the crankshaft position (CKP) sensor electrical connector and retaining clips.





27. Disconnect the injection control pressure (ICP) sensor electrical connector. Disconnect the glow plug electrical connector and wire retainers.





28. Disconnect the camshaft position (CMP) sensor electrical connector and retaining clips.





29. Disconnect the electrical connector and wire retainers at the transmission.





30. Disconnect the glow plug module electrical connectors.





31. Disconnect the exhaust pressure sensor electrical connector and pushpin retainer.





32. Disconnect the LH glow plug electrical connector.





33. Disconnect the 2 engine-to-vehicle electrical connectors.





34. Disconnect the 2 powertrain control module (PCM) electrical connectors and position the engine wiring harness aside.





35. Remove the 3 bolts and the oil filter assembly.





36. Remove the nut and remove the transmission cooling tubes support bracket off the stud.