Engine Replacement: Removal
WARNING: This page is about a different car, the 2003 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION:
TO AVOID FROM HAVING UNSTABLE VEHICLE ON THE HOIST, BE SURE TO PROPERLY POSITION VEHICLE. THIS SHOULD BE CONSIDERED WHEN MAJOR COMPONENTS ARE BEING REMOVED (ENGINE AND TRANSAXLE ASSEMBLIES).
- Disconnect negative battery cable and remove battery.
- Disconnect intake air temperature (IAT) sensor connector.
- Loosen clamp at air cleaner assembly.
- Remove pushpin attachment from outlet resonator/duct assembly to support bracket.
- Loosen clamp at throttle body assembly.
- Disconnect PVC fresh air vent hose at cam cover.
- Remove outlet resonator/duct assembly.
- Cover throttle body opening with a shop towel. Use shop air to remove any dirt around throttle body and intake manifold to cylinder head.
- Remove underhood fuse block (UHFB) fuse cover by separating clips on each side.
- Remove UHFB fuse cover.
- Remove inner UHFB fuse cover.
- Loosen three connector through bolts at top UHFB.
- Remove battery and electronic power steering feed wire connection nut and remove wire from UHFB stud.
- Release tabs on each side of UHFB with a screwdriver.
- Raise UHFB from connectors. Disconnect electrical connectors on side of UHFB.
- Remove UHFB from vehicle.
- Remove battery cable and harness attachment clips on side of battery tray/UHFB bracket assembly.
- Remove main connectors from UHFB housing.
- Lay battery positive cable over engine. (Battery cables will be removed with powertrain assembly.)
- Remove electrical harness clips to battery tray.
- Remove UHFB and battery tray bolts.
- Remove UHFB and battery tray.
- Disconnect electrical connectors at transaxle controller (TCM) near brake booster (if equipped).
- Remove engine-to-body ground bolt.
- Disconnect connector for rear O2 sensor.
- Remove vacuum hose with check valve from booster and lay across engine.
- Disconnect 8-way electrical connector.
- Remove main engine harness (Grey connector) and lay over engine assembly. (This will allow engine harness to be removed with powertrain.)NOTE: Do not remove shiftier cable from bracket before removing cable from transaxle range switch. Damage to manual shift linkage may occur.
- If equipped with automatic range transaxle, disconnect shifter cable from transaxle range switch by using a screwdriver. Slightly pry between shifter cable plastic retainer and transaxle range switch. (Automatic Only)NOTE: Do not use too much force when disconnecting the shift cables or damage may result.
- Disconnect shift lever cables from shift control housing by prying with even pressure using a Fascia Retainer Remover J36346 (or equivalent). (M/T Only)
- Disconnect shift lever cables from shift lever cable bracket. (M/T Only)
- Disconnect pressure line from clutch actuator cylinder by removing C-clip then pulling line away from clutch actuator cylinder. (M/T Only)
- Disconnect back-up lamp switch (1) and front wheel speed sensor (2). (M/T Only)
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Place shop towel on generator to prevent coolant from entering the generator assembly.
- Drain coolant.
- Disconnect upper radiator hose at engine cylinder head.
- Disconnect lower radiator hose at coolant pipe.
- Disconnect de-gas hose at surge tank.
- Disconnect surge hose at bottom of surge tank.
- Disconnect heater hoses from heater core at front of dash.
- Relieve fuel system pressure using Gauge Bar Set SA9127E. Refer to FUEL SYSTEM PRESSURE RELEASE .
- Disconnect Gauge Bar Set SA9127E after pressure has been relieved.
- Remove safety clip and disconnect fuel transfer line at quick connect from fuel line using Line Disconnect Set SA9805E.
- Disconnect purge hoses at rear of purge solenoid.
- Remove headlamp assemblies.
IMPORTANT: Radiator/condenser/fan assembly will stay in vehicle during engine removal.
- Using long tie straps, secure radiator/condenser fan assembly to radiator support assembly.
- Raise vehicle.
- Remove front left-hand (LH) wheel.
- Remove front LH wheel inner splash shield.
IMPORTANT: A piece of hardwood should be used between transaxle case and cradle assembly. This wood will support transaxle when LH mount bolts are removed.
- Install a piece of hardwood 1 in. x 2 in. x 4 in. between transaxle case and engine cradle assembly.
- Remove front right-hand (RH) wheel.
- Remove wheel inner splash shield.NOTE: Do not install wood under oil pan plug boss. Damage to oil pan may occur.
IMPORTANT: A piece of hardwood should be used between oil pan assembly and engine cradle. This wood will support engine when right-hand mount bolts are removed.
- Install a piece of hardwood 1 in. x 2 in. x 4 in. between engine oil pan and engine cradle assembly near crankshaft.
- Install Accessory Belt Tensioner Unloader J44811 tool onto tensioner.
- Remove accessory drive belt.
- Disconnect electrical connector at A/C compressor.
- Disconnect electrical connector at A/C pressure transducer (on line).
- Remove A/C compressor bolts.
- Support compressor and line assembly to body with support straps.
- Remove pushpins that retain air deflector assembly to cradle.
IMPORTANT: When transaxle lines are disconnected, new seals must be installed into transaxle to prevent potential for leak.
IMPORTANT: Fluid will leak when lines are disconnected. Place a drip pan to collect transaxle oil.
- Drain transaxle fluid.
- Disconnect transaxle lines from transaxle. (Automatic Only)
- Disconnect rear O2 sensor.
- Remove exhaust pipe-to-manifold flange bolts.
- Remove exhaust pipe to intermediate pipe nuts.
- Remove converter pipe assembly and support intermediate pipe assembly.
- Remove propshaft bolts to power takeoff unit (PTU) - AWD Only.
- Remove propshaft bolts at rear axle assembly - AWD Only.
- Remove propshaft support bracket-to-body bolts - AWD Only.
- Remove propshaft assembly - AWD Only.NOTE: Do not remove cable from bracket before disconnecting shifter cable from transaxle range switch. Damage to manual shift shaft may occur. (Automatic Only)
- If equipped with automatic, remove shifter cable from bracket assembly. (Automatic Only)
- Remove steering gear to intermediate shaft bolt.
- Remove tie rod to knuckle nuts.
- Separate tie rod assemblies from knuckle assemblies using Tie Rod SA91100C tool.
- Remove lower control arm cotter pins and nuts to knuckle assembly.
- Separate lower control arms to knuckle assemblies by using Lower Control Arm Separator J43828.
IMPORTANT: Stabilizer links will stay in vehicle connected to strut assembly on engine removal.
- Remove lower stabilizer link nuts to stabilizer bar.
- Remove left-hand axle shaft assembly from transaxle.
- Disconnect right-hand shaft assembly from intermediate drive shaft using Axle Shaft Removal J45341 tool with appropriate slide tool.
- Lower vehicle.
- Remove right-hand engine mount to engine bracket bolts. Engine should rest on wood blocks.
- Remove left-hand transaxle mount to transaxle bolts. Transaxle should rest on wood blocks.
- Raise vehicle on hoist.
IMPORTANT: During powertrain removal support vehicle body by placing a jack at rear of vehicle.
- Position engine support table under powertrain assembly.
IMPORTANT: Blocks of wood can be used between the front of cradle and oil pan to table to level powertrain during removal.
- With table positioned, fully raise table to contact with powertrain assembly.
- Remove cradle to body bolts.
IMPORTANT: When lowering engine/transaxle assembly, verify all brake lines, shifter cable and other components are free during removal.
- Lower engine table and raise body on hoist until engine/transaxle and cradle assembly is free from vehicle.