Removal

Engine Replacement

- Tools Required
- J 39580 Engine Support Table
- J 36221 Hydraulic Clutch Line Separator
- J 25034-C Power Steering Pump Pulley Remover
- J 25033-C Power Steering Pump Pulley Installer
- J 39549 Ball Joint/Tie Rod Separator
- J 21366 Converter Holding Strap
- J 41798 Engine Lifting Brackets
- J 38836 Pilot Bushing Installer/Clutch Alignment Arbor

Removal Procedure

Caution: Refer to Battery Disconnect Caution in Service Precautions.





1. Disconnect the negative battery cable.
2. Disconnect the positive battery cable.
3. Recover the air conditioning system.
4. Drain the engine oil.
5. Remove the fan shroud.
6. Remove the upper radiator (inlet) hose.
7. Remove the lower radiator (outlet) hose.
8. Remove the shift control closeout boot, if equipped with a manual transmission.
9. Relieve the fuel system pressure.





10. Remove the air conditioning (A/C) compressor and condenser hose bolt at the accumulator.
11. Discard the O-ring.





12. Remove the upper oil cooler line from the radiator.





13. Remove the air conditioning condenser tube nut.
14. Remove the condenser tube from the condenser.





15. Remove the inlet and outlet heater hoses from the water pump.
15.1. Squeeze the hose clamp together with pliers.
15.2. Slide the hose clamp away from the water pump fitting.
15.3. Gently twist and pull the heater hose from the water pump fitting.





16. Disconnect the fuel line from the fuel rail.
17. Disconnect the vapor line from the fuel vapor purge valve.





18. Remove the cruise control cable from the throttle lever.

Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle. In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.





19. Remove the accelerator control cable from the throttle lever.
20. Unsnap and remove the accelerator and cruise control cable from the throttle body bracket.





21. Remove the secondary Air Injection (AIR) hose (2) from the AIR shut-off valve (1).
22. Remove the brake booster vacuum hose.
23. Remove the front brake lines from the brake pressure modulator valve.





24. Disconnect the secondary captured locks.
25. Disconnect the forward lamp harness from the engine harness.
26. Disconnect the engine harness vacuum tube from the bottom of the vacuum check valve.





27. Disconnect the Powertrain Control Module (PCM) connectors.
28. Remove the PCM from the bracket.
29. Remove the right side insulator panel.
30. Remove the hinge pillar trim panel.





31. Disconnect the engine wiring harness from the instrument panel wiring harness.





32. Pull the engine wiring harness through the front of dash.
33. Lay the engine wire harness on top of the engine.
34. Raise and suitably support the vehicle. Refer to Vehicle Lifting.





35. Remove the lower oil cooler line from the radiator.
36. Remove the front wheels.
37. Disconnect ALL oxygen sensor electrical connectors.
38. Remove the exhaust crossover pipe.
39. Remove the driver side front fascia air deflector.





40. Remove the stabilizer bar bracket bolts/stud.
41. Remove the stabilizer bar brackets.





42. Remove the wiring harness ground bolt.
43. Reposition the RF (Radio Frequency) ground strap and cruise control ground lead away from the frame rail.





44. Unsnap the automatic transmission range selector lever cable from the range selector lever, if equipped.





45. Remove the automatic transmission range selector lever cable retainer, if equipped.





46. Unsnap the automatic transmission range selector lever cable from the bracket, if equipped.





47. If equipped with a manual transmission perform the following:
47.1. Using the J 36221, depress the white circular release ring on the actuator hose and simultaneously pull lightly on the master cylinder hose to disconnect.
47.2. Protect both ends from dirt and damage.
48. Remove the propeller shaft.
49. Remove the torque arm.





50. Remove the intermediate steering shaft bolt and shaft from the power steering rack.





51. Disconnect the left and right side wheel speed sensor electrical connectors.





52. Reposition the generator output terminal boot.
53. Remove the battery positive cable nut from the generator output stud.
54. Remove the positive lead from the generator.
55. Remove the starter motor.





56. Remove the right and left side shock absorber lower bolts.





57. Remove the cotter pins and nuts from the left and right upper ball joints.





58. Using J 39549 separate the upper control arms (2) from the steering knuckles (3).
59. Secure both steering knuckles.





60. Remove the front fuel pipe heat shield nuts (1).
61. Remove the front fuel pipe heat shield (2).
62. Open the fuel pipe clip (7).
63. Unclip the brake lines from the brake pipe clip.
64. Position the J 39580 below the vehicle.
65. Lower the vehicle until the crossmember is resting on the J 39580.
66. Secure the vehicle to the hoist.





67. Remove the front crossmember bolts.





68. Remove the transmission crossmember bolts.
69. Carefully raise the vehicle off of the engine and transmission assembly.
70. Secure the crossmember to the J 39580.





71. Remove the ignition coil(s) (as required) for the proper fit of the J 41798 before lifting the engine.
72. Install the J 41798 to the engine.





73. Install a ratchet with hex-head socket to the drive belt tensioner bolt.
74. Rotate the drive belt tensioner clockwise in order to relieve tension on the accessory drive belt.
75. Remove the drive belt from the tensioner and pulleys.
76. Slowly release tension on the drive belt tensioner.
77. Remove the ratchet and socket from the drive belt tensioner bolt.





78. Install a ratchet with hex-head socket on the A/C belt tensioner bolt.
79. Rotate the A/C drive belt tensioner clockwise in order to relieve tension on the drive belt.
80. Remove the A/C drive belt from the pulleys.
81. Slowly release tension on the A/C drive belt tensioner.
82. Remove the ratchet and socket from the A/C drive belt tensioner bolt.





83. Using J 25034-C, remove the power steering pump pulley.





84. Remove the power steering pump bolts (4), and brace (3) from the pump (1).
85. Reposition the power steering pump to the crossmember.





86. Remove the power steering pump bracket bolts and bracket.





87. Disconnect the A/C compressor electrical connector.
88. Remove the rosebud clip from the engine bracket.





89. Remove the A/C compressor bolts.
90. Remove the A/C compressor.





91. Remove the A/C compressor bracket bolts.
92. Remove the A/C compressor bracket.





93. Remove the left transmission cover bolt and cover, if equipped.





94. Remove the right transmission cover bolt and cover, if equipped.





95. Remove the torque converter bolts.





96. Remove the engine wiring harness clip bolt (1) from the automatic transmission, if equipped.
97. Disconnect the following electrical connectors from the automatic transmission, if equipped:
- 20-way connector (2)
- Vehicle speed sensor (3)





98. Remove the automatic transmission fill tube bolt.
99. Remove the rosebud clip (1) from the right side of the manual transmission, if equipped.
100. Disconnect the back-up lamp switch electrical connector (2).





101. Disconnect the following electrical connectors from the left side of the manual transmission, if equipped:
- Skip shift solenoid (1)
- Reverse lockout solenoid (2)
- Vehicle speed sensor (3)
102. Remove the push-in retainer (4) from the manual transmission tab.





103. Remove the generator rear bracket bolt (1).





104. Remove the generator bolts and transmission oil cooler clip.
105. Remove the generator.
106. Install a engine hoist to the J 41798





107. Remove the right side engine mount bolts and mount.





108. Remove the engine mount heat shield nuts and shield.





109. Remove the left side engine mount studs and mount.
110. Raise the engine using the J41798
111. With the aide of an assistant, lift the engine and transmission from the crossmember.
112. Support the transmission on the J 39580





113. Remove the automatic transmission bolts, if equipped.





114. Remove the manual transmission bolts (2), if equipped.
115. Separate the transmission from the engine.
116. Attach the J 21366 to the automatic transmission.





117. Remove the pressure plate bolts (4), if equipped.
118. Remove the pressure plate (3) and clutch disc (2) from the flywheel (1), if equipped.





119. Remove the engine flywheel bolts.
120. Remove the automatic transmission flywheel, if equipped.





121. Remove the manual transmission flywheel, if equipped.
122. Install the engine to a engine stand.
123. Remove the engine hoist from the engine block.





124. Remove the J 41798 from the engine block.





125. Remove the exhaust manifold pipe nuts (1).
126. Remove the left catalytic converter and gasket (2).





127. Remove the exhaust manifold pipe nuts (1).
128. Remove the right catalytic converter and gasket (2).





129. Disconnect the Connector Position Assurance (CPA) retainer (1).
130. Remove the rosebud clips (4) from the fuel rail.
131. Disconnect the following engine wiring harness electrical connectors:
- Idle Air Control (IAC) valve
- Throttle Position (TP) sensor
- Fuel injectors (3)
- Ignition coil (2)
- Canister purge valve (5)
- Air Injection Reaction (AIR) solenoid





132. Disconnect the CPA retainer (1).
133. Remove the rosebud clips (3) from the fuel rail.
134. Disconnect the following engine wiring harness electrical connectors:
- Fuel injectors (2)
- Ignition coil (4)





135. Remove engine wiring harness ground bolts (2, 3).
136. Disconnect the following engine wiring harness electrical connectors:
- Oil pressure sensor (1)
- Knock sensor harness (4)





137. Remove the engine wiring harness clip bolt (3).
138. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector (1).
139. Remove the vacuum hose (2) from the tee on the rear vacuum port.





140. Disconnect the following engine wiring harness electrical connectors:
- Oil level sensor (1)
- Crankshaft Position (CKP) sensor (2)
141. Remove the engine wiring harness from the engine.