Powertrain Assembly Removal

CAUTION: DO NOT ALLOW SMOKING OR THE USE OF OPEN FLAMES IN THE AREA WHERE WORK ON THE FUEL SYSTEM IS TAKING PLACE. ANY TIME THE FUEL SYSTEM IS BEING WORKED ON, DISCONNECT THE NEGATIVE BATTERY CABLE, EXCEPT FOR THOSE TESTS WHERE BATTERY VOLTAGE IS REQUIRED.






1. Disconnect negative battery cable and remove coolant bottle cap.

NOTICE: The engine's cooling system thermostat will not function correctly once it is contacted by oil. If oil is found in the cooling system, it must be flushed and the thermostat's cartridge replaced.

2. Drain engine coolant. Drains are located at right front corner of the engine block and right hand side of radiator.
3. Remove air induction system inlet hose or air cleaner assembly. Cover the throttle body opening with a shop towel.





4. Disconnect electrical and vacuum connectors where applicable:
a. Engine coolant temperature (ECT) sensor and coolant temperature sensor.
b. Oxygen sensor and clip at transaxle front mount bracket.
c. Idle air control (IAC) valve.
d. Ignition coil (two different connectors).
e. Throttle position (TP) sensor.
f. MAP sensor.
g. EGR solenoid.
h. Brake booster hose at brake booster or intake manifold.





i. Ground connectors (two, located at transaxle attachment studs at rear side of cylinder block.
j. Injector connector(s).








k. Automatic/manual transaxle connectors:
^ Neutral safety/selector switch (three connectors).
^ Valve body actuator connector.
^ Turbine speed sensor.
^ Transaxle temperature sensor.
^ Back-up light switch (manual transaxle).

IMPORTANT: The transaxle electrical connectors and shift cable(s) can also be removed after the vehicle is on a hoist and the left-hand side splash shield is removed.





5. Disconnect accelerator cable assembly.

CAUTION: CATCH LEAKING FUEL IN A CONTAINER WHENEVER FUEL LINES ARE LOOSENED OR DISCONNECTED.

6. Disconnect both fuel lines.
a. Fuel pressure can be bled into an approved container using Gauge Bar kit SA9127E.
b. Disconnect the fuel supply and return lines at connectors. Fuel lines can be tied to brake master cylinder lines to prevent fuel spill.





7. Disconnect the upper radiator hose at cylinder head outlet and deaeration hose at engine.

NOTICE: It is not necessary to discharge the A/C compressor during powertrain removal.






8. Remove A/C compressor (if equipped) bolts and tie the compressor to the front crossbar. Leave both A/C mounting brackets mounted on the engine.
9. Disconnect the automatic transaxle cooler lines at transaxle and plug.

IMPORTANT: Pinch the plastic connector tabs and pull on the line. Wrap the end of the lines in a clean shop towel to prevent debris entry.

Fig. 5 Transaxle Shifter Cable Removal.:

10. Disconnect the automatic transaxle shifter cable.





11. Manual transaxle shifter cables and clutch hydraulic system.
a. Remove the two hydraulic damper to clutch housing stud nuts and slide damper and bracket assembly off studs.
b. Rotate clutch actuator 1/4 turn counter clockwise while pushing toward housing to disengage the bayonet connector and remove from clutch housing.
c. Tie clutch hydraulic system to battery tray. Do not kink or pin. the nylon hydraulic lines.





12. Using safety wire or plastic tie straps, tie the radiator, condenser, and fan module to the front vehicle crossbar. The safety wire or plastic tie straps can be routed around the two fan shroud supports and around the crossbar.