Engine Removal

NOTE: Use fender covers to avoid damaging painted surfaces. To avoid damage, unplug the wiring connectors carefully while holding the connector portion. Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring or hoses, or interfere with other parts. Secure the hood in the wide open position (support rod in the lower hole). Make sure you have the anti-theft codes for the radio and navigation system, then write down the customer's radio station presets. Disconnect the negative cable from the battery first, then disconnect the positive cable. Remove the engine cover. Remove the battery. Remove the air cleaner housing. |

Remove the ground cable stay (A), harness clamp (B), and harness stay mounting bolt (C). Remove the two bolts (D), and loosen the two bolts (E) securing the battery base. Remove the battery base (F), then remove the loosened bolts (E). |

Remove the air intake cover (A), then remove the resonator (B). |

Remove the battery cables (A) from the under-hood fuse/relay box. Remove the glow control module (B) and harness clamps (C), then disconnect the harness connectors (D). |

Remove the under-hood fuse/relay box (A) from the fuse/relay box bracket. Remove the four bolts (B) securing the fuse/relay box bracket, and remove the bolt (C) securing the intercooler inlet pipe. |

Remove the harness clamps (A) and harness connector (B) from the fuse/relay box bracket. Remove the harness clamp (C) from the body, then remove the fuse/relay box bracket. |

Remove the intercooler inlet pipe Remove the clutch slave cylinder and clutch line bracket mounting nut. |

Remove the clutch line bracket. Remove the shift cable and select cable. |

Remove the intercooler outlet hose. Remove the fuel feed hose. |

Remove the fuel return hose (A) and brake booster vacuum hose (B). |

Disconnect the engine wire harness connectors (A). Remove the harness clamp (B). |

Disconnect the accelerator pedal position (APP) sensor connector (A). Remove the harness clamps (B) and grommet (C), then pull the engine wire harness through the bulkhead. Remove the drive belt. |

Remove the power steering (P/S) pump (A), and the P/S hose clamp (B). Do not disconnect the P/S hoses from the pump. Remove the expansion tank cap and air bleed cap. Raise the vehicle on the hoist to full height. Remove the front tyres/wheels. |

Remove the splash shield. Loosen the drain plug in the radiator, and drain the engine coolant. Drain the transmission fluid. Drain the engine oil. Disconnect the stabilizer links. Remove the damper forks. Disconnect the suspension lower arm ball joints. Remove the driveshafts. Coat all precision-finished surfaces with clean engine oil. Tie plastic bags over the driveshaft ends. |

Remove exhaust pipe A. Lower the vehicle on the hoist. |

Remove the expansion tank. |

Remove the upper radiator hose (A) and lower radiator hose (B). |

Remove the heater hoses. |

Disconnect the A/C condenser fan motor connector (A). Remove the two bolts (B), and loosen the two bolts (C) securing the A/C condenser fan shroud, then remove the A/C condenser fan shroud assembly (D). |

Remove the A/C compressor without disconnecting the A/C hoses. Raise the vehicle on the hoist to full height. |

Remove the lower torque rod. |

Remove the two bolts securing the transmission lower mount. Lower the vehicle on the hoist. |

Attach the chain hoist to the engine as shown. |

Remove the transmission upper mount bracket. |

Remove the transmission upper mount. |

Remove the ground cable (A), then remove the upper torque rod (B). |

Remove the side engine mount bracket. Check that the engine/transmission is completely free of vacuum hoses, fuel and coolant hoses, and electrical wiring. Slowly raise the engine/transmission assembly about 150 mm (6 in.). Check once again that all hoses and wires are disconnected from the engine/transmission. Raise the engine/transmission assembly all the way, and remove it from the vehicle. |