Part 1

Engine

Special Tool(s):

All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Release the fuel system pressure.
3. Remove the accessory drive belt.
4. Remove the battery tray.
5. Remove the power steering pump.

Vehicles equipped with air conditioning
6. Recover the A/C system.

All vehicles
7. Drain the engine cooling system.
8. Drain the engine oil.
^ Install the drain plug and tighten to 28 Nm (21 ft. lbs.).

9. Remove the 2 nuts and disconnect the catalytic converter from the muffler assembly.
^ Remove and discard the gasket.

10. Remove the 4 bolts and the catalytic converter support bracket.

11. NOTE: All 2.3L engines and some 2.0L engines are equipped with a heat shield that must be positioned aside to access the catalytic converter-to-engine nuts.

If equipped, remove the 4 heat shield bolts and position the heat shield aside.

12. Disconnect the exhaust sensor electrical connectors.

13. If equipped, disconnect the upper exhaust sensor electrical connector and retainer.

14. If equipped, disconnect the secondary air injection (AIR) hose.

15. Remove and discard the 7 catalytic converter-to-engine nuts.
^ Position aside the catalytic converter and support with mechanic's wire.
^ Remove and discard the catalytic converter gasket.

16. Loosen the clamp and disconnect the vent tube from the air cleaner outlet pipe.

17. Remove the 2 bolts and detach the air intake resonator from the grommets.
^ Remove the air intake resonator and outlet pipe.

18. Remove the accelerator control snow shield.
^ Detach the evaporative emissions (EVAP) hose pin-type retainer.
^ Remove the screw, the pin-type retainer and the snow shield.

19. Disconnect the accelerator cable and speed control cable (if equipped).
1 Disconnect the accelerator and speed control cable (if equipped) from the throttle body.
2 Remove the 3 bolts and position the accelerator control cables and bracket aside.

20. Disconnect the fuel tube quick connect coupling from the fuel rail and position the fuel tube aside.

21. Disconnect the evaporative emissions tube.

22. If equipped, disconnect the AIR hose.

23. If equipped, disconnect the AIR vacuum regulator electrical connector.

24. Disconnect the power brake booster vacuum tube.
^ Depress the quick connect locking ring.
^ Pull the vacuum tube out of the quick connect fitting.

25. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.

26. Disconnect the upper radiator hose, the heater hose and the coolant vent hose from the coolant bypass.

27. Remove the bolt and ground eyelet.

28. Disconnect the fuel charging wiring harness electrical connector and harness retainer.

29. Disconnect the fuel charging wiring harness electrical connector.

30. Disconnect the power distribution wiring harness electrical connector.

31. Detach the wiring harness retainers.

32. Remove the nut and the power distribution wiring harness eyelet.

33. Disconnect the 3 main engine wiring harness electrical connectors and detach the connectors from the bracket.

Vehicles equipped with a manual transmission

34. NOTE: Press the locking tab.

Detach the gearshift cables from the transaxle.
1 Detach the shifter cable from the shift mass.
2 Detach the selector cable from the selector lever.

35. Detach the gearshift cables from the bracket.
1 Detach the shifter cable from the retaining bracket, turning the abutment sleeves counterclockwise.
2 Detach the selector cable from the retaining bracket, turning the abutment sleeves counterclockwise.

36. WARNING: Escaping brake fluid. Do not allow brake fluid to come into contact with the skin or the eyes. If brake fluid does come into contact with the skin or eyes, rinse the affected areas with water immediately. Failure to follow these instructions may result in personal injury.

CAUTION: If brake fluid is spilled on the paintwork, the affected area must be immediately washed down with cold water.

Remove the clutch slave cylinder supply tube.
^ Remove the clip.
^ Remove the supply tube and secure it to one side using cable ties.

37. Disconnect the reversing lamp switch electrical connector.

Vehicles equipped with a 2.0L engine and automatic transmission
38. Disconnect the transmission shifter cable and position it aside.

39. Disconnect the transmission cooler hoses.