Removal
Removal ProcedureNotice: 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.
- Tools Required
- J33432-A Transverse Leaf Spring Compressor
- J25034-B Pump Pulley Remover
- J25033-B Pump Pulley Installer
- J42188 Ball Joint Separator
- J39580 Engine Support Table
- J39580 - 500 Engine Support Table Top
- J41798 Engine Lifting Brackets
- J42203 Driveline Support
- J34730 - 1A Fuel Pressure Gauge
- J36221 Hydraulic Clutch Line Separator
Caution: Refer to Battery Disconnect Caution In Service Precautions.
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. Reposition the air intake duct and the air cleaner assembly forward.
9. Remove the upper radiator support.
10. Remove the radiator.
11. Remove the Electronic Brake Control Module/Break Pressure Modulator Valve (EBTCM/BPMV) and bracket.
12. Reposition the brake pipes.
13. 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.
14. Remove the fuel line from the connector at front of the dash.
15. Remove the fuel rail covers.
16. Relieve the fuel system pressure using the J34730-1A.
17. Disconnect the fuel line at the fuel rail (1).
Important: Cap the hoses and inlets when separating the cooling system components, this prevents dirt and other contaminants from entering the cooling system.
18. Disconnect the radiator hoses from the water pump.
19. Disconnect the heater hoses from the water pump.
20. Disconnect the following electrical connectors from the top of the engine:
20.1. Fuel injectors
20.2. Ignition coil main harness connectors
20.3. Evaporative Emission (EVAP) solenoid
20.4. Electric throttle motor
20.5. Throttle Position Sensor (TPS)
20.6. Engine Coolant Temperature (ECT) sensor
20.7. Air conditioning compressor
21. Disconnect the generator electrical connectors.
22. Remove the generator.
23. Disconnect the brake booster vacuum hose from the brake booster.
24. Remove the intermediate shaft to steering gear bolt.
25. Disconnect the intermediate steering shaft from the steering gear and position it to the left onto the frame rail.
26. Disconnect the secondary Air Injection (AIR) hose from the left exhaust manifold.
Important: Do not remove the engine flywheel housing to driveline support assembly bolts until it is called out in the procedure.
27. Raise and suitably support the vehicle.
28. Remove both of the front tire and wheel assemblies.
29. Disconnect and unclip the Heated Oxygen Sensors (H02S) connectors from the intermediate exhaust pipes.
30. Remove the intermediate exhaust pipes.
31. Remove the close-out panel bolts.
32. Remove the close-out panel.
33. Remove the positive cables from the starter.
34. Remove the (S) cable from the starter.
35. Remove the starter bolts.
36. Remove the starter from the vehicle.
37. Remove all wiring harness clips from the right side and rear of the engine block.
38. Disconnect the oil level sensor electrical connector.
39. Disconnect the crank position sensor electrical connector.
40. Disconnect the right Heated Oxygen Sensor (HO2S) electrical connector.
41. Remove the Air Conditioning (AC) compressor hose assembly retaining bolt.
42. Remove the air conditioning compressor hose assembly from the AC compressor.
43. Disconnect the engine oil temperature sensor electrical connector.
44. Disconnect the left H02S electrical connector.
45. Remove the front stabilizer shaft.
46. Disconnect the electrical connectors and harness from the electric cooling fans.
47. Remove the electric cooling fan assembly by sliding the whole unit upwards.
48. Loosen the tie rod end nuts (3).
49. Separate the tie rod ends (5) from steering knuckles (4) using J42188.
50. Disconnect the Antilock Brake System (ABS) electrical connector clips from the crossmember (if equipped).
51. Disconnect the Electronic Variable Orifice Control (EVO) connector clips from the crossmember.
52. Disconnect the Real Time Damping (RTD) connector clips from the crossmember (if equipped).
53. Remove the shock absorber lower mounting bolts.
54. Remove the front transverse leaf spring.
55. Disconnect the automatic transmission cooler pipes at the engine flywheel housing junction (if equipped).
56. Disconnect the automatic transmission cooler pipe clamps from the front and the rear of the engine oil pan (if equipped).
57. Disconnect the automatic transmission cooler pipes from the radiator (if equipped).
Notice: Refer to Fastener Notice in Service Precautions.
Important: Failure to use the minimum fastener length specified will prevent proper retention of the propeller shaft during disassembly.
58. With automatic transmission vehicles, use the following steps:
58.1. Remove the two plug bolts in the driveline support assembly.
58.2. Install a M10.0 - 1.5 x 55 mm bolt or longer in each plug location.
Tighten the M10 bearing support bolts to 35 Nm (26 ft. lbs.).
59. With automatic transmission vehicles, remove the engine flywheel housing access plug.
60. Orientate the automatic transmission flywheel hub collar to access the bolt (1).
61. Position the collar bolt facing downward.
62. Loosen the automatic transmission flywheel hub collar bolt (1).
63. Unclip the wiring harness from engine and reposition it to the driveline.
Important: The weight of the engine should never be supported by J42203.
64. Install J42203 to the close-out panel flange.
65. Vehicles equipped with a manual transmission need to:
65.1. Unclip the clutch actuator hose from the engine flywheel housing clip.
65.2. Using J36221, depress the white circular release ring on the actuator hose and simultaneously pull lightly on the master cylinder hose to disconnect.
65.3. Protect both ends from dirt and damage.
65.4. Remove the engine flywheel housing bolts from the driveline support assembly.
Important: The weight of the engine should never be supported by J42203.
66. Install J42203 to the close-out panel flange.
67. Slowly lower the vehicle to the J39580 and J39560-500.
68. Support the engine and crossmember assembly on J39580 and J39580-500.
69. BY HAND, remove the front and rear crossmember nuts.
70. Partially raise the vehicle.
71. Remove the AIR tube bracket bolt and reposition the tube bracket to gain access to the left rear ground strap.
72. Remove the ground strap from the rear of left cylinder head.
73. Disconnect the following electrical connectors from the back of the engine:
73.1. Engine oil pressure sensor
73.2. Camshaft position sensor
73.3. Manifold absolute pressure (MAP) sensor
73.4. Knock sensor wire harness connector
73.5. All remaining electrical connections
74. Remove the front driveline support assembly bolts from the driveline.
Important: Visually inspect the wiring harness detachment from the engine.
75. Insert a flat bladed screwdriver, or similar tool, between the edge of driveline support assembly and the engine flywheel housing, then pry the engine loose from the driveline.
76. Slowly pull the engine away from the propeller shaft.
77. As soon as the propeller input shaft clears the engine flywheel housing, slowly raise the vehicle.
78. Slide the engine and crossmember assembly forward in order to clear the propeller shaft spline.
Important: Visually inspect the wiring harness clearances while raising the vehicle.
79. Raise the vehicle completely off of the engine and crossmember assembly.
Important: It is not necessary to open the power steering system during the engine removal procedure.
80. Remove the power steering pump pulley using J25034-B.
81. Remove the power steering pump bolts.
82. Remove the power steering pump and reservoir from the engine and reposition them to the crossmember.
83. Remove the Air Conditioning (AC) compressor belt.
84. Remove the air conditioning compressor bolts and nut.
85. Remove the air conditioning compressor stud and compressor from the engine.
86. Remove the air conditioning compressor bracket bolt and bracket.
87. Remove the AIR tube mounting bolts and tube from the exhaust manifolds.
88. Install J41798 to the engine.
89. Install a lifting device to the J41798.
90. Remove the spark plug wires from the spark plugs.
91. Remove the spark plugs from the cylinder heads.
92. Remove the engine mount to crossmember nuts.
93. Remove the engine from the crossmember, using J41798.
94. Remove the J41798 from the engine.