Section 1 (Engine - 3.5L GTDI): Removal: Engine
WARNING: This page is about a different variant/trim than selected.
SPECIAL TOOL(S)
| 2, 200# Floor Crane, Fold Away 300-OTC1819E or equivalent | |
| Adjustable Grip Arm, 1735A 014-00001 or equivalent | |
| Disconnect Tool, Transmission Cooler Line 307-569 | |
| Eye, Engine Lift 303-1245 | |
| Powertrain Lift 300-OTC1585AE or equivalent | |
| Spreader Bar 303-D089 (D93P-6001-A3) or equivalent |
WARNING:
Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
NOTE:
Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.
- 1.
With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking and Lifting .
- 2.NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).
Using a suitable holding device, hold the steering wheel in the straight-ahead position.
- 3.
Release the fuel system pressure. For additional information, refer to Fuel System - General Information .
- 4.
Recover the A/C system. For additional information, refer to Climate Control System - General Information and Diagnostics .
- 5.
Remove the front wheels and tires. For additional information, refer to Wheels and Tires .
- 8.
Drain the cooling system. For additional information, refer to Engine Cooling .
- 9.
Disconnect the LH Heated Oxygen Sensor (HO2S) electrical connector.- Detach the HO2S connector retainer from the bracket.
- 10.
Remove the cowl panel grille. For additional information, refer to Front End Body Panels .
- 15.
Remove the engine wiring harness retainer from the bulkhead.- 1.
Push the tab in.
- 2.
Slide the wiring harness up and out of the bulkhead.
- 1.
- 18.
Remove the degas bottle. For additional information, refer to Engine Cooling .
- 19.
Remove the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to Intake Air Distribution and Filtering .
- 20.
Disconnect the Turbocharger Boost Pressure (TCBP) /Charge Air Cooler Temperature (CACT) sensor electrical connector.
- 22.
Remove the battery tray. For additional information, refer to Battery, Mounting and Cables .
- 25.
Remove the nut and disconnect the power feed wires from the positive battery terminal.- Disconnect the electrical connector.
- 26.
Disconnect the brake booster vacuum hose quick connect coupling from the intake manifold. For additional information, refer to Fuel System - General Information .
- 28.
Disconnect the transaxle control cable from the shift cable bracket.- Detach the wiring harness pin-type retainer.
- 34.
Disconnect the Evaporative Emission (EVAP) tube quick connect coupling. For additional information, refer to Fuel System - General Information .
- 36.
Disconnect the quick connect coupling from the intake manifold and remove the EVAP tube assembly. For additional information, refer to Fuel System - General Information .
- 37.
Disconnect the fuel supply tube from the High-Pressure Fuel Pump (FP) tube. For additional information, refer to Fuel System - General Information .
- 38.
Remove the 2 front suspension height sensors. For additional information, refer to Vehicle Dynamic Suspension .
- 40.
Remove the LH and RH catalytic converters. For additional information, refer to Exhaust System .
- 41.NOTE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring may occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to Supplemental Restraint System .
Remove the bolt and disconnect the steering column shaft from the steering gear.
- Discard the bolt.
- 42.NOTE: Index-mark the driveshaft for installation.
Remove and discard the 4 bolts and position aside the driveshaft.
- 43.
Remove the drain plug and drain the engine oil.- Install the drain plug and tighten to 27 Nm (20 lb-ft).
- 46.
Remove the nut and disconnect the upper A/C tube from the compressor.- Discard the O-ring seal and gasket seal.
- 51.
Remove the 2 secondary latches from the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
- 52.
Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal bypass valve.
- 58.NOTE: Do not allow the brake caliper to hang from the brake flexible hose or damage to the hose may occur.NOTE: LH shown in illustration, RH similar.
Remove the brake caliper guide pin bolts and calipers.
- Support the calipers.
- 59.NOTE: RH shown in illustration, LH similar.
Using a wax pencil, mark the relationship of the front and rear subframe to the underbody at the mounting locations on both side.
- 60.NOTE: LH shown in illustration, RH similar.
Remove the LH and RH halfshaft nuts.
- Do not discard at this time.
- 61.NOTE: LH shown in illustration, RH similar.
Separate the LH and RH halfshaft from the wheel hubs.
- 62.
Position a 2 x 6 board, 36 in (914.4 mm) in length and two 2 x 6 boards 24 in (609.6 mm) in length onto the powertrain lift.- Position the powertrain lift table with:
- the long board towards the rear of the subframe.
- the short boards under the engine and transmission.
- Position the powertrain lift table with:
- 63.
Install the Adjustable Grip Arm from the powertrain lift table to the LH engine-to-transmission bolt hole.
- 64.
Install a ratchet strap from the front of the subframe under the powertrain lift table to the rear of the subframe, to secure the subframe to the powertrain lift table.
- 65.NOTE: LH shown in illustration, RH similar.NOTE: The halfshafts are not being remove from the transmission.
Remove the strut-to-wheel knuckle nuts and bolts.
- Remove the strut from the wheel knuckle and the halfshafts from the wheel knuckle.
- 70.NOTE: RH shown in illustration, LH similar.
Remove the rear subframe bolts and the subframe brackets.
- 80.
Install a ratchet strap from the RH knuckle to the subframe to keep the RH halfshaft from coming out of the PTU or transmission.
- 88.
Disconnect the A/C compressor and the pressure relief valve electrical connectors.- Detach the wiring harness retainers.
- 94.
Remove the ratchet strap from the front of the subframe under the powertrain lift table to the rear of the subframe.
- 95.NOTE: LH shown in illustration, RH similar.
Install the ratchet strap from the front subframe to the LH engine lift eye and from the rear of the subframe to the RH engine lift eye.
- 96.
Using the Floor Crane and Spreader Bar, remove the powertrain and subframe as an assembly from the powertrain lift table and set on the ground.- Position wood blocks under the engine and transmission.
- 97.NOTE: LH shown in illustration, RH similar.
Remove the ratchet strap from the front subframe to the LH engine lift eye and from the rear of the subframe to the RH engine lift eye.