Removal
REMOVAL PROCEDURE^ Tools Required
- J 33432-A Transverse Leaf Spring Compressor
- J 25034-B Pump Pulley Remover
- J 25033-B Pump Pulley Installer
- J 42188 Ball Joint Separator
- J 39580 Engine Support Table
- J 39580-500 Engine Support Table Top
- J 41798 Engine Lifting Brackets
- J 42203 Driveline Support
- J 34730-1A Fuel Pressure Gauge
- J 36221 Hydraulic Clutch Line Separator
The steps in the following procedure are in a specific order. Follow these steps in this order and do not ignore any details or vehicle damage may occur.
1. Disconnect the negative battery cable.
2. Raise the vehicle and support.
3. Drain the coolant.
4. Lower the vehicle.
5. Recover the air conditioning system refrigerant.
6. Disconnect the Intake Air Temperature sensor (IAT) connector.
7. Disconnect the Mass Air Flow (MAS) sensor connector.
8. Disconnect the fuel pressure regulator purge tube from the air intake duct.
9. Reposition the air intake duct and the air cleaner assembly forward.
10. Remove the upper radiator support.
11. Remove the top radiator hose.
12. Remove the radiator.
13. Remove the Electronic Brake Control Module/Break Pressure Modulator Valve (EBTCM/BPMV) and bracket.
14. Reposition the brake pipes.
15. Remove the accessory drive belt (5).
IMPORTANT: Cap the fittings and plug the holes when separating fuel system components this prevents fuel, dirt and other contaminants from entering the fuel system.
16. Remove the left fuel line from the connector at front of the dash.
17. Remove the engine beauty covers.
18. Relieve the fuel system pressure using the J 34730-1A.
19. Disconnect the fuel lines (3 and 4) at the fuel rail.
IMPORTANT: Cap the hoses and inlets when separating the cooling system components, this prevents dirt and other contaminants from entering the cooling system.
20. Disconnect the radiator hoses from the water coolant pump.
21. Disconnect the heater hoses from the water coolant pump.
22. Disconnect the following electrical connectors from the top of the engine:
22.1. Fuel injectors
22.2. Ignition coil main harness connectors
22.3. Evaporative Emission (EVAP) solenoid
22.4. Electric throttle motor
22.5. Throttle Position Sensor (TPS)
22.6. Engine coolant temperature (ECT) sensor
22.7. Air conditioning compressor
23. Disconnect the generator electrical connectors.
24. Remove the generator mounting bolts.
25. Remove the generator.
26. Remove the generator mounting bracket bolt and bracket.
27. Disconnect the brake booster vacuum hose from the brake booster.
28. Remove the intermediate shaft to steering gear bolt.
29. Disconnect the intermediate steering shaft from the steering gear and position it to the left onto the frame rail.
30. Disconnect the Air Injection Reaction (AIR) hose from the left exhaust manifold.
IMPORTANT: Do not remove the engine flywheel housing to driveling support assembly bolts until it is called out in the procedure.
31. Raise the vehicle.
32. Remove both of the front tire and wheel assemblies.
33. Disconnect and unclip the Heated Oxygen Sensors (H02S) connectors from the intermediate exhaust pipes.
34. Remove the intermediate exhaust pipes.
35. Remove the close-out panel bolts.
36. Remove the close-out panel.
37. Remove the positive cables from the starter.
38. Remove the (S) cable from the starter.
39. Remove the starter bolts.
40. Remove the starter from the vehicle.
41. Remove all ground wires from the right side and rear of the engine block.
42. Disconnect the oil level sensor electrical connector.
43. Disconnect the crank position sensor electrical connector.
44. Disconnect the right heated oxygen sensor (H02S) electrical connector.
45. Remove the air conditioning (AC) compressor hose assembly retaining bolt.
46. Remove the air conditioning compressor hose assembly from the AC compressor.
47. Disconnect the engine oil temperature sensor electrical connector.
48. Disconnect the left H02S electrical connector.
49. Disconnect all ground wires from the left side of the engine block.
50. Remove the front stabilizer bar bolts and straps.
51. Remove the front stabilizer bar nuts from the lower control arms.
52. Remove the front stabilizer bar from the vehicle.
53. Disconnect the electrical connectors and harness from the electric cooling fans.
54. Remove the electric cooling fan assembly by sliding the whole unit upwards.
55. Install J 33432-A to the front spring.
56. Compress the front spring using the J 33432-A.
57. Remove the tie rod end nuts (3).
58. Remove the tie rod ends (5) from steering knuckles (4) using J 42188.
59. Disconnect the Antilock Brake System (ABS) electrical connectors at the cradle (if equipped).
60. Disconnect the Electronic Variable Orifice Control (EVO) connector at the cradle.
61. Disconnect the Real Time Damping (RTD) connectors at the cradle (if equipped).
62. Remove the shock absorber lower mounting bolts.
63. Remove the front transverse leaf spring using J 33432-A.
64. Disconnect the automatic transmission cooler lines at the engine flywheel housing junction (if equipped).
65. Disconnect the automatic transmission cooler lines from the radiator (if equipped).
66. With automatic transmission vehicles, use the following steps:
66.1. Remove the two plug bolts in the driveling support assembly.
IMPORTANT: Failure to use the minimum fastener length specified will prevent proper retention of the propeller shaft during disassembly.
66.2. Install a M10.0 - 1.5 x 55 mm or longer in each plug location.
^ Tighten the M10 bearing support bolts to 35 Nm (26 ft. lbs.).
67. With automatic transmission vehicles, remove the engine flywheel housing access plug.
68. Orientate the automatic transmission flywheel hub collar to access the bolt (1).
69. Position the collar bolt facing downward.
70. Loosen the automatic transmission flywheel hub collar bolt (1).
71. Unclip the wiring harness from engine and reposition it to the driveling.
IMPORTANT: The weight of the engine should never be supported by J 42203.
72. Install J 42203 to the close-out panel flange.
73. Vehicles equipped with a manual transmission need to:
73.1. Unclip the clutch actuator hose from the engine flywheel housing clip.
73.2. Using J 36221, depress the white circular release ring on the actuator hose and simultaneously pull lightly on the master cylinder hose to disconnect.
73.3. Protect both ends from dirt and damage.
73.4. Remove the engine flywheel housing bolts from the driveling support assembly.
IMPORTANT: The weight of the engine should never be supported by J 42203.
74. Install J 42203 to the close-out panel flange.
75. Slowly lower the vehicle to the J 39580 and J 39580-500.
76. Support the engine and cradle assembly on J 39580 and J 39580-500.
77. BY HAND, remove the front and rear cradle nuts.
78. Partially raise the vehicle.
79. Remove the AIR tube bracket bolt and reposition the tube bracket to gain access to the left rear ground strap.
80. Remove the ground strap from the rear of left cylinder head.
81. Disconnect the following electrical connectors from the back of the engine:
81.1. Engine oil pressure sensor
81.2. Camshaft position sensor
81.3. Manifold Absolute Pressure (MAP) sensor
81.4. Knock sensor wire harness connector
81.5. All remaining electrical connections
82. Remove the front driveling support assembly bolts from the driveling.
IMPORTANT: Visually inspect the wiring harness detachment from the engine.
83. Insert a flat bladed screwdriver, or similar tool, between the edge of driveling support assembly and the engine flywheel housing, then pry the engine loose from the driveline.
IMPORTANT: During this procedure take extra care in making sure that the radiator is not damaged.
84. Slowly pull the engine away from the propeller shaft.
85. As soon as the propeller input shaft clears the engine flywheel housing, slowly raise the vehicle.
86. Slide the engine and cradle assembly forward in order to clear the propeller shaft spline.
IMPORTANT: Visually inspect the wiring harness clearances while raising the vehicle.
87. Raise the vehicle completely off of the engine and cradle assembly.
IMPORTANT: It is not necessary to open the power steering system during the engine removal procedure.
88. Remove the power steering pump pulley using J 25034-B.
89. Remove the power steering pump bolts.
90. Remove the power steering pump and reservoir from the engine and reposition them to the cradle.
91. Remove the air conditioning (AC) compressor belt.
92. Remove the air conditioning compressor bolts and nut.
93. Remove the air conditioning compressor stud and compressor from the engine.
94. Remove the air conditioning compressor bracket bolt and bracket.
95. Remove the AIR tube mounting bolts and tube from the exhaust manifolds.
96. Install J 41798 to the engine.
97. Install a lifting device to the engine.
98. Remove the spark plug wires from the spark plugs.
99. Remove the spark plugs from the cylinder heads.
100. Remove the engine mount to cradle nuts.
101. Remove the engine from the cradle.
102. Remove the J 41798 from the engine.