Removal Procedure
- Recover the refrigerant. Refrigerant Recovery and Recharging
- Relieve the fuel system pressure. Fuel Pressure Relief
- Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection (KL9)
- Front Wheelhouse Liner- Left Side and Right Side - Remove [ 2x ] - Front Wheelhouse Liner Replacement
Hood Latch Actuator Bolt (1) - Remove [ 2x ]
- Hood Secondary Latch Release Handle (2) - Remove
Intake Air Baffle Retainer (1) - Remove [ 9x ]
- Intake Air Splash Shield (2) - Remove
- NOTE:
Left side shown, right side similar.
Remove the left and right side front bumper fascia bolt (1).
- NOTE:
Left side shown, right side similar.
Loosen the 2 left and right side front bumper fascia guide bolts (1).
- Remove the left and right side front bumper fascia bolt (2).
Front Bumper Fascia Skid Plate Bolt (1) - Remove [ 4x ]
- NOTE:
Left side shown, right side similar.
Remove the left and right side front bumper fascia support brace bolts (1).
Front Grille Bolt (1) - Remove [ 6x ]
Apply a double layer of masking tape to the left and right headlamp to prevent damaging / scratching the headlamp lens.
- On the left and right side of the front bumper fascia (1) carefully push a small nylon wedge between the front bumper fascia and the front bumper fascia guide. Insert a suitable flat-bladed plastic trim tool, into the fascia slot and depress the snaps one at a time and pull on the fascia at the same time to gradually remove front bumper fascia
- Starting at the inside of the headlamp, release the front bumper fascia (1) from the headlamps.
{ If equipped } Disconnect the electrical connectors.
- Release the 7 grille clips (1).
- With the aid of an assistant, remove the fascia. (2)
- NOTE:
The proper position of the underbody skid shield is between the front bumper fascia extension and the front frame.
Underbody Skid Shield Bolt (1) - Remove [ 4x ]
- Underbody Skid Shield (2) - Remove
- Drain the coolant
Cooling System Draining and Filling (GE 47716 L84, L87) , or
- Drain the engine oil. Engine Oil and Oil Filter Replacement
- WARNING:
Refer to Safety Glasses Warning .
CAUTION:Always turn the ignition off when installing or removing the ECM connectors in order to prevent damage to the components.
CAUTION:- Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage.
- Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery.
- In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board.
- Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module.
- The replacement control module must be programmed.
Disconnect the electrical connectors. (1)
- NOTE:
Parts removed from graphic for clarity.
Disconnect the electrical connector. (1)
{ If equipped } Engine Coolant Heater Cord (1) @ Engine Coolant Heater - Disconnect
Air Cleaner Outlet Duct Bracket Bolt (1) - Remove
- Engine Wiring Harness @ Air Cleaner Outlet Duct Bracket - Remove
Air Cleaner Outlet Duct Clamp (2) - Loosen [ 2x ]
- Positive Crankcase Ventilation Fresh Air Tube (1) - Disconnect - Plastic Collar Quick Connect Fitting Service
- Air Cleaner Outlet Duct (3) - Remove
Headlamp Bolt (1) - Remove [ 6x ]
Headlamp Bolt (1) - Remove [ 6x ]
Release the front headlamp guide pin from the front bumper fascia guide (1).
- Front Headlamp (2) - Remove [ 2x ]
- Release the wiring harness retaining tab.
- Disconnect all electrical connectors.
Loosen the left and right side front bumper fascia upper stiffener nut (1).
- Remove the left and right side front bumper fascia upper stiffener bolt (2).
Pull the front bumper fascia upper stiffener (1) up and out over the stud.
Front Bumper Shutter Bolt (1) - Remove [ 9x ]
- Disconnect the electrical connector and reposition wiring harness.
- Front Bumper Shutter (2) - Remove
Intake Air Duct Retainer (1) - Remove
- Intake Air Duct (2) - Remove
Disconnect the mass airflow sensor electrical connector (1) and remove all engine wiring harnesses from the air cleaner assembly.
Air Cleaner Nut (1) - Remove
- Air Cleaner Assembly (2) - Remove
Plenum Front Panel Outer Reinforcement (1) - Remove - Plenum Front Panel Outer Reinforcement Removal and Installation
Radiator Air Side Baffle Retainer (1) - Remove [ 4x ]
- Radiator Air Side Baffle - Remove
Radiator Air Side Baffle Retainer (2) - Remove
- Radiator Air Side Baffle - Left Side (1) - Remove
Front End Sheet Metal Diagonal Brace Bolt (1) @ Upper Tie Bar - Remove [ 4x ]
- Front End Sheet Metal Diagonal Brace (2) @ Upper Tie Bar - Remove [ 2x ]
Release the 6 integral retaining features (1).
- Radiator Air Upper Baffle (2) - Remove
- NOTE:
Right side shown, left side similar.
Front End Sheet Metal Diagonal Brace Bolt- Left Side and Right Side (1) - Remove [ 4x ]
- Front End Sheet Metal Diagonal Brace- Left Side and Right Side (2) @ Radiator Support - Remove [ 2x ]
Reposition the hood primary latch release cable (1) from the upper tie bar retainer (2).
- Hood Primary Latch Release Cable (1) - Disconnect @ Hood Primary Latch
- Disconnect the electrical connector.
Electrical Connector (2) - Disconnect
Front Grille Support Bracket Bolt (1) - Remove [ 4x ]
- Front Grille Support Reinforcement (2) - Remove
Front End Upper Tie Bar Bolt- Left Side (1) - Remove [ 3x ]
Front End Upper Tie Bar Bolt- Right Side (1) - Remove [ 3x ]
Front End Upper Tie Bar Bolt (1) @ Headlamp Bracket - Remove [ 2x ]
- Front End Upper Tie Bar Bolt (2) - Remove
Front End Upper Tie Bar Bolt- Right Side (1) - Remove
Front End Upper Tie Bar Bolt (1) @ Headlamp Bracket - Remove [ 8x ]
- Headlamp Bracket (2) - Remove [ 2x ]
Front End Upper Tie Bar (1) - Remove
- Disconnect the wiring harness from the front end upper tie bar.
Radiator Surge Tank Inlet Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Radiator Surge Tank Inlet Hose (2) @ Engine Radiator - Remove and position aside
Retaining Tab (1) - Disengage [ 2x ]
- Engine Wiring Harness Junction Block Cover (2) - Remove
- Battery Positive Cable Nut (3) - Remove
- Starter Solenoid Cable (4) - Remove
Engine Wiring Harness Junction Block Bolt (2) - Loosen [ 4x ]
- Retaining Tab (1) - Disengage [ 4x ]
- Engine Wiring Harness Junction Block (3) - Remove
Electrical Connector (1) - Remove [ 4x ]
Engine Wiring Harness Fuse Block Bracket Bolt (2) - Remove [ 2x ]
- Retaining Tab (1) - Disengage
- Engine Wiring Harness Fuse Block Bracket (3) - Remove
Heater Outlet Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Radiator Surge Tank Outlet Hose Clip (2) - Remove [ 2x ]
- Radiator Surge Tank Outlet Hose (3) @ Heater Outlet Hose - Remove and position aside
- NOTE:
Some components not shown for graphic clarity.
Radiator Inlet Hose Clip (2) - Remove
- Radiator Inlet Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Radiator Inlet Hose (3) @ Engine Radiator - Remove and position aside
- NOTE:
Some components not shown for graphic clarity.
Wiring Harness Retainer (1) - Remove [ 2x ]
- Electrical Connector (3) - Disconnect
- Wiring Harness (2) - Position aside
- NOTE:
Some components not shown for graphic clarity.
Wiring Harness Retainer (2) - Remove [ 2x ]
- Electrical Connector (1) - Disconnect
- Wiring Harness (3) - Position aside
Engine Oil Cooler Retainer (2) - Remove [ 2x ]
- Engine Oil Cooler Pipe Bracket Bolt (3) - Remove
- Engine Oil Cooler Hose (1) @ Engine Radiator - Remove [ 2x ]
Transmission Fluid Auxiliary Cooler Pipe Bolt (1) - Remove
- Transmission Fluid Cooler Pipe Clip (2) - Remove [ 2x ]
Transmission Fluid Cooler Pipe Nut (1) - Remove
- Transmission Fluid Cooler Inlet and Outlet Pipe (2) @ Transmission Fluid Auxiliary Cooler - Remove and position aside
- Transmission Fluid Cooler Pipe Fitting Seal (3) - Remove and DISCARD
Transmission Fluid Cooler Pipe Nut (1) - Remove
Transmission Fluid Cooler Inlet and Outlet Pipe (1) @ Transmission Fluid Auxiliary Cooler - Remove and position aside
- Transmission Fluid Cooler Pipe Fitting Seal (2) - Remove and DISCARD
Transmission Fluid Cooler Pipe Clip (1) - Release
Air Conditioning Compressor and Condenser Hose Nut (1) - Remove
- Air Conditioning Compressor and Evaporator Hose Nut (2) - Remove
Air Conditioning Compressor and Condenser Hose (1) @ Air Conditioning Condenser - Remove
- Air Conditioning Condenser and Evaporator Hose (3) @ Air Conditioning Condenser - Remove
- Air Conditioning Compressor and Condenser Hose Seal (2) - Remove and DISCARD [ 2x ]
Radiator Inlet Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Radiator Outlet Hose (2) @ Engine Radiator - Remove
Rotate the top of the condenser, fan and radiator assembly (1) rearward and lift it out of the engine compartment.
Heater Inlet Hose (3) @ Heater Inlet and Outlet Hose Clip (1) - Remove
Heater Outlet Hose (3) @ Heater Inlet and Outlet Hose Clip (1) - Remove
- Heater Outlet Hose Clamp (4) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Heater Outlet Hose (3) @ Radiator Surge Tank Outlet Hose - Remove
- Heater Outlet Hose Clip (2) @ Heater Water Auxiliary Pump Hose - Remove
- NOTE:
The accessory drive primary belt is not reusable.
Some components not shown for graphic clarity.
Using a suitable tool, cut the accessory drive primary belt (1).
- Accessory Drive Primary Belt (1) - Remove and DISCARD
- NOTE:
The accessory drive auxiliary belt is not reusable.
Using a suitable tool, cut the accessory drive auxiliary belt (1).
- Accessory Drive Auxiliary Belt (1) - Remove and DISCARD
Battery Positive Cable Nut (1) - Remove
- Starter Solenoid Cable (2) - Remove
- Electrical Connector (3) - Disconnect
Generator Bolt (1) - Remove [ 2x ]
Generator (1) - Remove
Hose Clamp (1) - Disengage [ 2x ] - Hose Clamp Replacement Guidelines - Spring Type
- Heater Inlet Hose (2) @ Water Pump - Remove
- Heater Water Auxiliary Pump Hose (3) @ Water Pump - Remove
Radiator Outlet Hose Clamp (1) - Disengage - Hose Clamp Replacement Guidelines - Spring Type
- Radiator Outlet Hose (2) @ Water Pump - Remove
Hose Clamp (1) - Disengage [ 2x ] - Hose Clamp Replacement Guidelines - Spring Type
- Engine Coolant Air Bleed Hose (2) @ Water Pump - Remove
- Radiator Inlet Hose (3) @ Water Pump - Remove
Engine Coolant Temperature Sensor Electrical Connector (1) - Disconnect
Electrical Connector (1) @ Air Conditioning Compressor - Disconnect
Air Conditioning Compressor Bolt (1) - Remove
- Air Conditioning Compressor Nut (2) - Remove
- Air Conditioning Compressor Stud (3) - Remove
Air Conditioning Compressor (1) - Position aside
Water Pump Housing Bolt (1) - Remove [ 6x ]
Water Pump (1) - Remove
- Water Pump Gasket (2) - Remove and DISCARD [ 2x ]
Evaporative Emission Canister Purge Tube Connector (1) @ Evaporative Emission Canister Purge Solenoid Valve - Disengage - Plastic Collar Quick Connect Fitting Service
- Evaporative Emission Canister Purge Tube (2) @ Evaporative Emission Canister Purge Solenoid Valve - Remove and position aside
Engine Wiring Harness Connector (1) @ Throttle Body - Disconnect
- Engine Wiring Harness Retainer (2) @ Intake Manifold Cover - Remove [ 2x ]
- Engine Wiring Harness Connector (3) @ Manifold Absolute Pressure Sensor - Disconnect
- Engine Wiring Harness Connector (4) @ Evaporative Emission Canister Purge Solenoid Valve - Disconnect
Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) - Remove [ 4x ]
Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) - Remove [ 3x ]
Positive Crankcase Ventilation Tube Connector (2) @ Intake Manifold - Disconnect and reposition - Plastic Collar Quick Connect Fitting Service
- NOTE:
Some components not shown for graphic clarity.
Loosen the 10 intake manifold bolts (1) until the bolts are no longer threaded into the cylinder heads.
- Move the intake manifold and intake manifold cover (2) forward enough to gain access to the rear engine wiring harness retainers.
Engine Wiring Harness Retainer (1) @ Intake Manifold Cover (2) - Remove [ 4x ]
- NOTE:
The aid of an assistant may be helpful in holding the engine harness up out of the way so the upper intake manifold cover does not get caught against the engine harness.
Remove the intake manifold and intake manifold cover (1) as an assembly.
- Cover the cylinder head passages in order to prevent dirt or debris from entering the passages.
Intake Manifold Gasket (1) - Remove and DISCARD [ 8x ]
- WARNING:
The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.
Fuel Pump Insulator (1) - Remove
Fuel Feed Pipe (1) - Disconnect - Metal Collar Quick Connect Fitting Service
- Fuel Feed Pipe (1) - Reposition
- CAUTION:
Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution .
CAUTION:To tighten or loosen the fuel injection fuel rail fuel pressure sensor, apply force ONLY to the attached hexagon. Applying force to the plastic housing of the sensor may damage the sensor.
Electrical Connector (1) @ Fuel Rail Pressure Sensor (2) - Disconnect
- Fuel Rail Pressure Sensor (2) @ Fuel Injection Fuel Rail (3) - Remove
Install the EN-36857 Engine Lift Bracket (1) using the EN-52059 Engine Support Fixture Adapter Bolt - M10 (2) to the cylinder head and hand tighten.
Install the EN-36857 Engine Lift Bracket (1) using the EN-52059 Engine Support Fixture Adapter Bolt - M10 (2) to the cylinder head and hand tighten.
Air Conditioning Compressor and Condenser Hose - Position aside
- NOTE:
Some components not shown for graphic clarity.
Electrical Connector @ Heater Coolant Pump (2) - Disconnect
- Heater Water Auxiliary Pump Bolt (1) - Remove
- Remove the heater coolant pump and heater water auxiliary pump bracket (2) as assembly and position aside.
Starter Heat Shield Bolt (1) - Remove [ 2x ]
- NOTE:
Catalytic converter removed for graphic clarity.
Starter Heat Shield Bolt (1) - Remove
- Starter Heat Shield (2) - Remove
Battery Negative Cable Ground Bolt (1) - Remove
- Starter Solenoid Cable (2) - Reposition away
Starter Mounting Bolt (1) - Remove [ 2x ]
- Reposition the starter (2) to access the electrical connections.
Protective Sleeve (4) - Reposition
- Starter Solenoid Cable Nut (2) - Remove
- Starter Solenoid Cable (1) - Remove
- Electrical Connector (3) - Disconnect
Starter (1) - Remove
Transmission Converter Cover Bolt (1) - Remove
- Transmission Converter Cover-Left Side (2) - Remove
Transmission Converter Cover Bolt (1) - Remove
- Transmission Converter Cover-Right Side (2) - Remove
Engine Oil Cooler Hose Bracket Nut (1) - Remove
Engine Oil Pressure Sensor Sleeve (1) - Remove
Electrical Connector (1) @ Engine Oil Pressure Sensor - Disconnect
- Wiring Harness Retainer (2) @ Engine Oil Cooler Hose - Remove
Engine Oil Cooler Hose Bolt (1) - Remove [ 2x ]
Engine Oil Cooler Hose (1) @ Oil Pan - Reposition
- Engine Oil Cooler Gasket (2) - Remove and DISCARD
Remove the transmission fluid auxiliary cooler pipe bracket nut (1).
- Remove the transmission fluid cooler inlet and outlet pipe bracket (2) from the engine.
Engine Wiring Harness Retainer (2) - Remove
- Engine Wiring Harness Ground Stud (1) - Remove [ 2x ]
- Engine Wiring Harness (3) @ Oil Pan - Reposition
Transmission Fluid Cooler Pipe Clip Bolt (1) @ Oil Pan - Remove
- Transmission Fluid Cooler Pipe Clip Bracket (2) @ Oil Pan - Remove
Reposition the transmission cooler inlet and outlet pipe (1) as necessary.
{ If equipped } Remove the 3 wiring harness retainers (1) from the transmission support crossmember, and reposition the wiring harness (2) as necessary.
- Support the transmission with a suitable jack.
Transmission Mount Nut (1) - Remove
Transmission Support Crossmember Nut (1) - Remove [ 4x ]
- Transmission Support Crossmember Bolt (2) - Remove [ 4x ]
Transmission Support Crossmember (1) - Remove
Exhaust Heat Shield Bolt- Left Side (1) - Remove
- Exhaust Front Pipe Heat Shield- Left Side (2) - Remove
Exhaust Heat Shield Bolt- Right Side (1) - Remove
- Exhaust Front Pipe Heat Shield- Right Side (2) - Remove
- WARNING:
Avoid contact with HOT components. Wear safety glasses and protective gloves to avoid personal injury.
CAUTION:Refer to Heated Oxygen and Oxygen Sensor Caution .
NOTE:- The heated oxygen sensor in-line connector and louvered end MUST be kept clear of all grease, dirt, and other contaminants. Do NOT use cleaning solvents of any type. Do NOT drop or roughly handle the heated oxygen sensor (1).
- The heated oxygen sensor (1) MAY be difficult to remove when the engine temperature is less than 48°C (120°F).
Electrical Connector @ Heated Oxygen Sensor- Bank 1 Sensor 1 - Disconnect
- Using a suitable tool, remove the heated oxygen sensor (1).
- WARNING:
Avoid contact with HOT components. Wear safety glasses and protective gloves to avoid personal injury.
CAUTION:Refer to Heated Oxygen and Oxygen Sensor Caution .
Electrical Connector @ Heated Oxygen Sensor- Bank 1 Sensor 2 - Disconnect
- WARNING:
Avoid contact with HOT components. Wear safety glasses and protective gloves to avoid personal injury.
CAUTION:Refer to Heated Oxygen and Oxygen Sensor Caution .
NOTE:- The heated oxygen sensor in-line connector and louvered end MUST be kept clear of all grease, dirt, and other contaminants. Do NOT use cleaning solvents of any type. Do NOT drop or roughly handle the sensor.
- The heated oxygen sensor MAY be difficult to remove when the engine temperature is less than 48°C (120°F).
Electrical Connector @ Heated Oxygen Sensor- Bank 2 Sensor 1 - Disconnect
- Using a suitable tool, remove the heated oxygen sensor (1).
- WARNING:
Avoid contact with HOT components. Wear safety glasses and protective gloves to avoid personal injury.
CAUTION:Refer to Heated Oxygen and Oxygen Sensor Caution .
Electrical Connector @ Heated Oxygen Sensor- Bank 2 Sensor 2 - Disconnect
- WARNING:
Avoid contact with HOT components. Wear safety glasses and protective gloves to avoid personal injury.
Exhaust Pipe Clamp (1) - Loosen
- Exhaust Muffler (2) @ Three-Way Catalytic Converter (3) - Separate
- WARNING:
In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.
Exhaust Front Pipe Nut- Left Side (1) - Remove [ 3x ]
- WARNING:
In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.
Exhaust Front Pipe Nut- Right Side (1) - Remove [ 3x ]
- WARNING:
Avoid contact with HOT components. Wear safety glasses and protective gloves to avoid personal injury.
Three-Way Catalytic Converter (1) - Remove
Exhaust System Seal (1) - Remove and DISCARD
Exhaust System Seal (1) - Remove and DISCARD
Repeat the following steps for all transmission torque converter bolts (1):
- Rotate the harmonic balancer center bolt clockwise ONLY, to align the transmission torque converter bolt with the starter opening.
- Transmission Torque Converter Bolt (1) - Remove [ 6x ]
- Lower the transmission to gain access to the top and sides of the transmission.
Remove the transmission vent hose clip bracket nut (1).
- Remove the transmission vent hose clip bracket (2) from the transmission.
Remove the fuel feed and return front hose bracket nut (1).
- Remove the fuel feed and return front hose bracket bolt (2).
- Reposition the fuel feed and return front hose (3) as necessary.
Transmission Stud (1) - Remove [ 5x ]
- Raise the transmission to the original installation position.
Transmission Support Crossmember (1) - Install
Transmission Support Crossmember Bolt (2) - Install [ 4x ]
- Transmission Support Crossmember Nut (1) - Install and hand tighten [ 4x ]
Transmission Mount Nut (1) - Install and hand tighten
Transmission Stud (1) - Remove
- Transmission Bolt (2) - Remove [ 2x ]
- Remove the support and lower the vehicle.
- CAUTION:
Broken engine mountings can cause misalignment of certain drive-train components. Misalignment of drive-train components causes eventual destruction of the drive-train components.
If one engine mount breaks, the rest of the engine mounts will have increased stress put on them. This could cause the rest of the engine mounts to break.
NOTE:Work through the front wheelhouse opening to access the 3 engine mount frame side bolts (1).
Engine Mount Frame Side Bolt- Left Side (1) - Remove [ 3x ]
- CAUTION:
Broken engine mountings can cause misalignment of certain drive-train components. Misalignment of drive-train components causes eventual destruction of the drive-train components.
If one engine mount breaks, the rest of the engine mounts will have increased stress put on them. This could cause the rest of the engine mounts to break.
NOTE:Work through the front wheelhouse opening to access the 3 engine mount frame side bolts (1).
Engine Mount Frame Side Bolt- Right Side (1) - Remove [ 3x ]
- Install a suitable chain to the two engine lift brackets to support the engine.
- Use a suitable stand to support the transmission.
- Ensure that all electrical connectors are disconnected at this time.
- Using a suitable engine lifting device, remove the engine from the vehicle.
Install the DT-21366 Converter Holding Strap (1) onto the transmission to retain the torque converter.
Mount the engine (1) onto the engine stand (2).
- Using the appropriate tool, clean and prepare the applicable sealing surface.
Some fuel may leak from the fuel rail pressure sensor orifice after the sensor is removed. Dry the area around this orifice after the removal of the sensor using a lint free cloth and inspect the fuel rail pressure sensor sealing surface. The surface should be free of fuel, debris, and burrs.
Components removed in graphic to better illustrate service parts.