Special tool
 Engine Lifting Winch 303-1144 |  Spring Lock Release Tool 310-D005 |  Ball Joint Puller 205-754(LRT-54-027) |
Removal
1. Place the vehicle on a lift.
2. Disconnect the ground cable from the battery. For more information, refer to Specification
3. Secure the hood in the service position.
4. Remove the battery tray. For more information, refer to Battery Installation Shelf (76.10.30)
5. Remove the extra battery tray. For more information, refer to Extra Battery Shelf (76.10.31)
6. Remove the air cleaner assembly. For more information, refer to Air Cleaner (10/19/01)
7. Remove the accessory drive belt. For more information, refer to Accessory Drive Belt (86.10.03)
8. Drain the coolant. For more information, refer to Draining/Filling Coolant and Bleeding the Cooling System (10/26/01)
9. Disconnect the lower coolant expansion tank hose. Release the clamp.
10. Disconnect the coolant hoses from the thermostat housing. Release the 2 clamps.
11. Disconnect the upper coolant hose assembly. Release the 2 clamps.
12. Disconnect the engine oil cooler coolant hoses.
- Release the 2 clamps.
- Remove the hose assembly.
13. To gain access, move the hose assembly to the side and tie it. Remove the bolt.
14. Remove the accessory drive belt tensioner. Remove the bolt.
15. Remove the fender splash guards. For more information, refer to Fender Splash Guard (76.10.48)
16. Remove the exhaust system. For more information, refer to Exhaust System (10/30/08)
17. Drain the engine oil. For more information, refer to Draining and Filling Engine Oil (12.60.05)
18. Disconnect the power steering pump, move it to the side and tie it up. Remove the 3 bolts.
19. Disconnect the air conditioning compressor, move it to the side and tie it up. Remove the 3 bolts.
20. Disconnect the transmission cooling system pipes.
- Place a container to collect any spilled liquid.
- Remove the bolt.
- Release the 2 clamps.
- Move the transmission pipes to the side.
21. Release the faceplate.
- Remove the sealing sleeve.
- Turn the crankshaft to gain access to the mounting bolts.
- Remove 3 bolts.
22. Disconnect the positive battery cable from the BJB.
- Remove the bolt.
- Move the positive wire to the side.
23. Disconnect the evaporative emission control system canister hose from the intake manifold. Move the hose aside to gain access.
24.
CAUTION: Before disconnecting or disassembling parts, make sure the area around the contact surfaces is clean and dry. To avoid contamination of the system, cover all open connections.
Move the EGR valve to the side.
- Remove 4 bolts.
- Remove the gasket and discard it.
25. Install the special tool.
26. Disconnect the engine wiring harness.
- Release the cassette.
- Loosen and disconnect the 2 electrical connectors.
- Remove the ground wire bolt.
27. Disconnect the brake booster vacuum hose from the intake manifold.
28. Release the pressure in the fuel rail. Place an absorbent cloth underneath to collect the leaking fluid.
29. Using the special tool, disconnect the fuel line. Move the fuel supply line to the side.
30. Release the heat shield fastening to gain access to the transmission mounting bolts.
- Remove 2 bolts.
- Move the screen to the side.
31. Remove the gearbox mounting bolts.
- Support the gearbox.
- Remove 16 bolts.
32. To gain access, remove the upper control arm and brake line heat shields.
- Remove 3 bolts.
- Unscrew 3 nuts.
33. Loosen the Allen bolt and rotate the engine oil cooler to the side to gain access.
34. Unscrew the 2 engine mount nuts.
35. Disconnect the engine from the supports and gearbox.
- Attach the lifting chains.
- Raise the right side of the engine approximately 35mm.
- Remove the 4 bolts securing the engine support bracket to the cylinder block.
- Disconnect the engine ground wire from the right support bracket.
37.
CAUTION: Make sure the torque converter remains attached to the transmission.
CAUTION: Be careful not to damage the steering rack and differential.
Carefully and gradually lift and remove the engine.
38. Disconnect the lifting chains.
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