Removal & Installation: Engine: Removal

WARNING: This page is about a different car, the 2003 Saturn Vue and 2002 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.

Disconnect the negative battery cable. Remove the battery cover and battery. Remove the air cleaner assembly.
Remove the Under Hood Fuse Block (UHFB) fuse cover by separating the clips on each side. Remove the UHFB fuse cover and inner fuse cover. Loosen the 3 connector through bolts at the top of the UHFB. Mark and disconnect engine harness connectors from UHFB. Remove the battery and the electronic power steering feed wire connection nut and remove the wire from the UHFB stud. Release the tabs on each side of the UHFB with a screwdriver. Mark all remaining engine connectors from UHFB. Remove the UHFB from the vehicle.
Remove the battery cable and the harness attachment clips the on side of battery tray/UHFB bracket assembly. Remove the main connectors from the UHFB housing. Lay the battery positive cable wire over the engine. The battery cables will be removed with powertrain assembly.
Disconnect the electrical connectors at the Transaxle Control Module (TCM) near the brake the booster. Disconnect the electrical connector for the rear O2 sensor and cut the tie strap to the heater hoses. Remove the vacuum hose from the check valve from the brake booster and lay across the engine. Remove the main engine harness Gray connector and lay over the engine assembly. This will allow the engine harness to be removed the with powertrain.
Remove the UHFB, battery tray bolts, battery tray and ground wire. Disconnect the shifter cable from the PRNDL switch by using a screwdriver. Slightly pry between the shifter cable plastic retainer and the PRNDL switch.
Place a shop towel on the generator to prevent coolant from entering the generator assembly. Drain the coolant in suitable container. See COOLING SYSTEM BLEEDING . Disconnect the upper radiator hose from the thermostat housing. Disconnect the lower radiator hose at the coolant pipe. Disconnect the surge hose at the bottom of the surge tank. Disconnect the heater hoses from the heater core at the front of the dash.
Relieve the fuel system pressure. See FUEL PRESSURE RELEASE . Disconnect the fuel transfer line at the quick connect from the fuel line using the Fuel Line Separator (SA9805E) or equivalent. Disconnect the purge hoses at the rear of the purge solenoid.
NOTE: Radiator/condenser/fan assembly will stay in the vehicle during the engine removal.
Using the long tie straps, secure the radiator/condenser fan assembly to the body. Perform an evacuation of the A/C system. Disconnect the A/C transducer and compressor.
WARNING: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.
Raise and support the vehicle. Remove the left front wheel/tire assembly and inner splash shield.
Install a piece of hardwood 1" x 2" x 4" between the transaxle case and the engine cradle assembly.
Remove the right front wheel/tire assembly. Remove the wheel inner splash shield. Remove the compressor and support the A/C line. Remove the push-pins that retain the air deflector assembly to the cradle.
NOTE: When the transaxle lines are removed, NEW seals must be installed into the transaxle to prevent the potential for a leak. Fluid will leak when the lines are disconnected. Place an appropriate container under vehicle to collect the transaxle oil.
Disconnect the transaxle lines from the transaxle. Remove the exhaust manifold to pipe flange bolts. Remove the exhaust pipe to muffler pipe nuts. Remove the converter pipe assembly and support the muffler and pipe assembly. Remove the drive shaft bolts at the Power Transfer Unit (PTU).
Remove the drive shaft bolt at the rear axle assembly. Remove the drive shaft support bracket-to-body bolts. Remove the drive shaft assembly. Remove the shifter cable bracket assembly nut and free the bracket with cable from the transaxle.
Remove the steering gear-to-intermediate shaft bolt. Remove the tie rod-to-knuckle nuts. Separate the tie rod assemblies from the knuckle assemblies using the Tie Rod Separator (SA91100C). Remove the lower control arm cotter pins and nuts to knuckle assembly. Separate the lower controls arm-to-knuckle assemblies by use the Ball Joint Separator (J-43828).
NOTE: The stabilizer links will stay in the vehicle connected to the strut assembly on engine removal.
Remove the lower stabilizer link nuts-to-stabilizer bar. Disconnect the left axle shaft assembly from transaxle. Using Rear Wheel Drive Shaft Remover (J-45341) and appropriate slide hammer, disconnect right shaft assembly from the intermediate drive shaft. Support the axle shaft by using tie straps. Lower the vehicle.
Remove right engine mount-to-engine bracket bolts. The engine should rest on wood blocks. Remove left transaxle mount-to-transaxle bolts. The transaxle should rest on wood blocks.
CAUTION: Ensure that vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

NOTE: Blocks of wood can be used between the front of the cradle and oil pan to table to level assembly during removal.
Raise and support the vehicle. Position the engine support table under the powertrain assembly. With the table positioned, fully raise the table to contact with the powertrain assembly. Remove the cradle-to-body bolts. When lowering the engine/transaxle assembly, verify all brake lines, shifter cable and other components are free during removal. Lower the engine table and raise the body on a hoist until the engine/transaxle and cradle assembly is free from the vehicle.