Step 1-51

Removal Procedure

Important: The steps in the following procedure are in a specific order. Follow these steps in this order and do not ignore any details or vehicle damage may occur.

- Tools Required
- J 33432-A Transverse Leaf Spring Compressor
- J 25034-C Pump Pulley Remover
- J 25033-C Pump Pulley Installer
- J 42188 Ball Joint Separator
- J 39580 Engine Support Table
- J 39580-500 Engine Support Table Top
- J 41798 Engine Lifting Brackets
- J 42203 Driveline Support
- J 34730-1A Fuel Pressure Gauge
- J 36221 Hydraulic Clutch Line Separator

Caution: Refer to Battery Disconnect Caution in Service Precautions.





1. Disconnect the negative battery cable.
2. Raise the vehicle and support. Refer to Vehicle Lifting.
3. Drain the coolant. Refer to Draining and Filling Cooling System in Cooling System.
4. Lower the vehicle.
5. Recover the air conditioning system refrigerant. Refer to Refrigerant Recovery and Recharging in Heating and Air Conditioning.





6. Disconnect the intake air temperature sensor (IAT) connector.
7. Disconnect the mass air flow (MAS) sensor connector.





8. Reposition the air intake duct and the air cleaner assembly forward.
9. Remove the upper radiator support.
10. Remove the radiator. Refer to Radiator Replacement in Cooling System.
11. Remove the Electronic Brake Control Module/ Break Pressure Modulator Valve (EBTCM/BPMV) and bracket. Refer to Brake Pressure Modulator Valve (BPMV) Bracket Replacement in Brakes and Traction Control.
12. Reposition the brake pipes.





13. Remove the accessory drive belt (5).

Important: Cap the fittings and plug the holes when separating fuel system components this prevents fuel, dirt and other contaminants from entering the fuel system.





14. Remove the fuel line from the connector at front of the dash.
15. Remove the fuel rail covers.
16. Relieve the fuel system pressure using the J 34730-1A. Refer to Fuel Pressure Relief Procedure in Powertrain Management.





17. Disconnect the fuel line at the fuel rail (1).

Important: Cap the hoses and inlets when separating the cooling system components, this prevents dirt and other contaminants from entering the cooling system.





18. Disconnect the radiator hoses from the water pump.





19. Disconnect the heater hoses from the water pump.





20. Disconnect the following electrical connectors from the top of the engine:
- The fuel injectors
- The ignition coil main harness connectors
- The evaporative emission (EVAP) solenoid
- The electric throttle motor
- The throttle position sensor (TPS)
- The engine coolant temperature (ECT) sensor
- The air conditioning compressor





21. Disconnect the generator electrical connectors.





22. Remove the generator. Refer to Generator Replacement in Starting and Charging.





23. Disconnect the brake booster vacuum hose from the brake booster.





24. Remove the intermediate shaft to steering gear bolt.
25. Disconnect the intermediate steering shaft from the steering gear and position it to the left onto the frame rail.





26. Disconnect the secondary air injection (AIR) hose from the left exhaust manifold.

Important: Do not remove the engine flywheel housing to driveline support assembly bolts until it is called out in the procedure.

27. Raise and suitably support the vehicle.
28. Remove both of the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Steering and Suspension.
29. Disconnect and unclip the heated oxygen sensors (HO2S) connectors from the intermediate exhaust pipes.
30. Remove the intermediate exhaust pipes. Refer to Intermediate Pipe Replacement in Exhaust System.





31. Remove the close-out panel bolts.
32. Remove the close-out panel.





33. Remove the positive cables from the starter.
34. Remove the (S) cable from the starter.





35. Remove the starter bolts.
36. Remove the starter from the vehicle.
37. Remove all wiring harness clips from the right side and rear of the engine block.





38. Disconnect the oil level sensor electrical connector.
39. Disconnect the crank position sensor electrical connector.
40. Disconnect the right heated oxygen sensor (H02S) electrical connector.





41. Remove the air conditioning (AC) compressor hose assembly retaining bolt.
42. Remove the air conditioning compressor hose assembly from the AC compressor.





43. Disconnect the engine oil temperature sensor electrical connector.
44. Disconnect the left H02S electrical connector.





45. Remove the front stabilizer shaft. Refer to Stabilizer Shaft Replacement in Steering and Suspension.





46. Disconnect the electrical connectors and harness from the electric cooling fans.





47. Remove the electric cooling fan assembly by sliding the whole unit upwards.





48. Loosen the tie rod end nuts (3).
49. Separate the tie rod ends (5) from steering knuckles (4) using J 42186.
50. Disconnect the antilock brake system (ABS) electrical connector clips from the crossmember (if equipped).