Removal
WARNINGDO NOT SMOKE, CARRY LIGHTED TOBACCO OR AN OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY.
WARNING
FUEL SUPPLY TUBES WILL REMAIN PRESSURIZED FROM LONG PERIODS OF TIME AFTER ENGINE IS SHUT DOWN. THIS PRESSURE MUST BE RELIEVED BEFORE SERVICING OF THE FUEL SYSTEM IS BEGUN.
NOTE:
Before disconnecting any fuel tube, release the fuel pressure from the fuel system to reduce the possibility of injury or fire. Use a rag as protection from the fuel spray when disconnecting the hoses. Plug the hoses after disconnection.
1. Relieve fuel system pressure as follows:
a. Remove the LH engine compartment relay panel cover.
b. Remove the fuel pump relay from the LH engine compartment relay panel. See Figure 2.
c. Start the engine.
d. After the engine stalls, crank the engine over two more times to ensure all the pressure has been released.
e. Turn the ignition switch off and install the fuel pump relay.
WARNING
THE ELECTRIC COOLING FAN MAY COME ON AT ANY TIME WHEN THE IGNITION SWITCH IS IN THE ON POSITION.
2. Drain cooling system as follows:
a. Turn the ignition switch to the On position and set the front temperature control panel selectors in the following positions: turn the front blower switch to 4, the front temperature control knob to the full WARM position, the rear control switch to the 4 position, and the mode selector switches to any mode except OFF.
b. For vehicles with a rear heater, set the rear blower switch to 4 and the rear temperature control knob to the full WARM position.
c. Turn the ignition switch OFF.
d. Remove the RH engine and transmission splash shield.
NOTE:
Do not use a galvanized drain pan if the coolant is going to be reused.
e. Position a drain pan under the radiator.
f. Open the radiator draincock at the bottom of the radiator inlet tank.
CAUTION
Do not allow coolant to contact the drive belts or they will be damaged.
g. Remove the radiator cap from the filler neck. If the system is hot and pressurized, carefully release the pressure before fully opening the radiator cap.
h. Position drain pan under cylinder block, then remove the rear and front cylinder block drainplugs. See Figure 3.
3. Place a suitable container underneath the oil pan drain plug. Remove the oil pan drain plug and allow the engine oil to drain into the container. After the oil has drained out of the oil pan, install the oil pan drain plug. Tighten the oil pan drain plug to 29-39 Nm (22-29 lb-ft).
4. Remove oil filter.
5. Install memory saver, then remove the battery.
6. Remove the air cleaner intake tube bracket bolt, then the air cleaner intake tube and the engine air intake resonator No. 1.
7. Disconnect the radiator overflow hose from the radiator filler neck.
8. Remove the radiator coolant recovery reservoir.
9. Disconnect the following electrical connectors from the left-hand side of the engine compartment:
^ Vehicle speed sensor
^ Starter motor
^ Transmission range (TR) switch
^ Mass air flow (MAF) sensor
^ Camshaft position (CMP) sensor
^ Pulse signal generator
^ Transaxle solenoid assembly/Transaxle fluid temperature
^ Ground wire from transaxle fill tube bracket
^ Connector C197 (refer to EVTM for connector location). Detach connector from transaxle.
10. Disconnect and plug the fuel tubes.
11. Disconnect the evaporative emission (EVAP) canister vacuum hoses. See Figure 4.
12. Remove the ignition coil cover, then disconnect the ignition coil electrical connector.
NOTE:
Do not pull on the ignition coil to distributor high tension wiring when removing it from the ignition coil.
13. Remove ignition coil to distributor high tension wiring. When removing the high tension wiring from the ignition coil grasp the boot by hand and remove it with a twisting and pulling motion.
14. Disconnect the following main engine wiring harness electrical connectors, located on the right-hand side of the engine compartment:
^ A/C compressor clutch pulley
^ A/C pressure cut-off switch
^ Power Transistor
^ Distributor
^ Engine coolant temperature (ECT) sensor
^ Coolant Temperature Sensor
^ Connector C147 (refer to the EVTM for connector location)
^ Connector C149 (refer to the EVTM for connector location)
^ Connector C189 (refer to the EVTM for connector location)
15. Detach main engine wiring harness from its mounting brackets on the engine.
16. Remove the two (2) ignition coil bolts and the ignition coil.
17. If equipped, disconnect the speed control actuator cable from the throttle lever.
18. Disconnect the accelerator cable from the throttle lever.
19. If equipped, remove the speed control actuator cable from the accelerator cable clip.
20. Remove the accelerator cable from the bracket attached to the top of the upper intake manifold.
21. Remove the two (2) bolts holding the accelerator cable/speed control actuator bracket to the upper intake manifold and position aside.
22. Loosen the upper radiator hose clamp and disconnect the upper radiator hose from the radiator.
23. Loosen the lower radiator hose clamp and disconnect the lower radiator hose from the coolant crossover tube.
24. If equipped, loosen the A/C compressor drive belt idler pulley tensioner bolt and remove the A/C compressor drive belt.
25. If equipped, loosen the two (2) upper A/C compressor bolts. See Figure 5. Bolts must be free from mounting brackets.
26. Disconnect the heater water hoses.
27. Disconnect the brake booster hose from the upper intake manifold.
28. Raise and support the vehicle.
29. Remove the inner and outer engine and transmission splash shields.
30. Remove the shift cable nut from the TR switch. Slide the shift cable and bracket off of the TR switch. See Figure 6.
31. Use a screwdriver to release the shift cable locking pin from the transmission shift cable bracket. Remove the shift cable and bracket from the transmission shift cable bracket. See Figure 7.
32. Disconnect the oil pressure sensor electrical connector. See Figure 8.
33. Disconnect the alternator electrical connector.
34. Remove the B-terminal nut and alternator ground wire nut from the alternator and position the wires aside. See Figure 9.
35. Remove the alternator wiring bracket bolt from the back of the alternator.
36. Disconnect the HO2S and block heater electrical connectors. Position body main harness aside.
37. Loosen the alternator lock nut and the adjustment bolt.
38. Loosen the front and rear alternator-to-alternator regulator mounting bracket bolts and remove the alternator drive belt.
39. Loosen the water pump/power steering pump drive belt idler pulley locknut.
40. Loosen the water pump/power steering pump drive belt adjustment bolt and remove the water pump and power steering pump drive belt.
NOTE:
Access the front power steering pump-to-bracket bolts from the front of the power steering pump.
41. Remove the three (3) front and one (1) rear power steering pump-to-bracket bolts and position the power steering pump aside.
42. If equipped, remove the two (2) lower A/C compressor bolts and position the A/C compressor aside. See Figure 10.
43. Remove exhaust inlet pipe as follows:
a. Remove the exhaust system flex tube bracket bolt and slide the exhaust system flex tube clamp out of the way.
b. Remove the two (2) exhaust inlet pipe/WU-TWC-to-exhaust system flex tube bolts.
c. Remove the three (3) exhaust manifold-to-exhaust inlet pipe/WU-TWC nuts.
d. Remove the exhaust inlet pipe/WU-TWC.
e. Discard the two (2) exhaust manifold-to-exhaust inlet pipe/WU-TWC gaskets.
f. Discard the exhaust inlet pipe-to-exhaust system flex tube gasket.
44. Remove both front wheel driveshafts and joints as follows:
a. Remove the lug nuts and the front wheel and tire assemblies.
b. Remove and discard cotter pin retaining front axle wheel hub nut.
c. Remove the nut retainer and insulator.
d. Remove the front axle wheel hub nut.
e. Remove the front wheel outer bearing retainer washer.
f. Remove the cotter pin from the front suspension lower arm ball joint. Discard the cotter pin.
g. Loosen the front suspension lower arm ball joint nut until it contacts the front wheel driveshaft joint.
h. Strike the front wheel knuckle with a soft-faced hammer while pulling down on the front suspension lower arm until the front suspension lower arm ball joint separates from the front wheel knuckle.
i. Remove the front suspension lower arm ball joint nut.
j. Remove the front stabilizer bar link-to-front suspension lower arm nut.
k. Carefully pry down on the front suspension lower arm and separate the front suspension lower arm ball joint from the front wheel knuckle.
l. Use a prybar and separate the front stabilizer bar link from the front suspension lower arm.
m. Separate the front wheel driveshaft and joint from the wheel hub.
n. Position drain pans under the transaxle.
CAUTION
Extreme care must be used to ensure that the prybar does not damage the transaxle case, differential oil seal, out race or boot.
o. If removing the LH front wheel driveshaft and joint, position prybars on both sides of the outer race, between the outer race and the transaxle case. Gently pry outward to unseat the circlip. See Figure 11.
p. After removing the LH front wheel driveshaft joint, pry the circlip off of the front wheel driveshaft. Discard the circlip.
NOTE:
When removing the RH front wheel driveshaft joint, it is not necessary to remove the front axle bearing retainer bracket from the cylinder block.
q. Remove the three (3) front axle bearing retainer-to-bracket bolts. See Figure 12.
r. Pull the RH front wheel driveshaft joint from the differential side gear.
s. Support the front wheel driveshaft and joints and slide them out of the vehicle. Be careful not to damage the front wheel driveshaft joint boots. Place the front wheel driveshaft and joints on a flat, protected work area.
45. Mark, disconnect and plug the transaxle fluid cooler hoses.
46. Disconnect the transaxle ground strap. See Figure 13.
NOTE:
Place blocks of wood on the Rotunda Power Train Lift with Tilting Plate 014-00765 or equivalent to prevent damage to underbody components.
47. Position the Rotunda Train Lift with Tilting Plate 014-00765 or equivalent, with the blocks of wood, under the engine and transaxle assembly. See Figure 14
48. Remove the three (3) rear transaxle support bracket nuts. See Figure 15.
49. Remove front transaxle support insulator through bolt.
50. Remove the two (2) rear refrigerant/heater pipe hold-down bracket bolts. See Figure 16.
51. Remove two (2) front engine insulator mounting bolts.
52. Remove two (2) rear engine insulator mounting bolts.
53. Remove four (4) transverse member bolts. Remove the transverse member.
54. Carefully lower the engine and transaxle from the engine compartment.
55. Remove the exhaust system flex tube bracket from the engine.
56. Remove the two (2) rear transaxle-to-engine brace bolts.
57. Remove the five (5) front transaxle-to-engine brace bolts.
58. Place a socket on the crankshaft pulley bolt to prevent the crankshaft from shipping, then remove the four (4) torque converter-to-flywheel bolts.
59. Remove the starter motor.
60. Remove the upper and lower transaxle-to-engine bolts.
61. Separate the transaxle from the engine.
62. Remove the flywheel from the engine.
63. Attach the engine to an engine stand.