Wow... just showeredd and removed a LOT of grime, my work clothes were filthy. Today took my pa over and we attempted to pull the engine on the 2.4 Sky. I did not have my Helm manual yet, and the *#&% crappy All-Data or whatever it was lacked a lot of detail on how to remove the engine. So, like usual I winged it.
Drained coolant. Removed radiator hoses. Dad started disconnecting the wire harnesses on the engine. I removed the radiator bracket, plastic cowling in front, the electric fan, Disconnected the power steering belt which is separate on the 2.4 for some reason - packaging I guess they could not match the serpentine belt to it. Removed serp. belt, alternator. disconnected the exhaust, removed the cat, and then in order to find a place to lift the rear of the motor, I removed the exhaust manifold and used one of those bolts. Removed the bolts on top of bellhousing facing toward motor. On the intake side, boy is the 2.4 cramped! That rams horn intake and brake booster, ABS system and all that totally blocked getting at the belhousing bolts.
Had to remove the air cleaner and induction part, throttle body, injector harness in order to remove the intake manifold. Some of the bolts for intake are blocked by the throttle body. Lots of grounded things on the block.
There is a bellhousing bolt by the starter, which is buried under all that stuff. We found out to remove the block from the trans/bellhousing, you have to remove the starter and rotate engine around to access the bolts holding the torque converter to the flex plate. these gave us fits, 18mm and very sturdy, also very cramped and difficult to put muscle to. Not a straight shot, did not get them off. Next day will remove that side engine mount and have hoist hold the engine, then I can get a impact gun to have a straight shot at the darn thing.
Also, FWIW, if you ever have a problem with the ac compressor, you might be in for a LOT of labor. I'm not sure how anyone can remove the lower bolt w/o lifting the engine or possibly removing the steering rack, but the *(#&@ thing is very cramped and difficult to access. We opted to leave it until we have the engine lifted up a few inches so I can access it with a socket. Otherwise, it was near impossible with the angle and access. Removing a wheel and working from the side was somewhat better, but frame was in the way.
In the end, we did not get the torque converter bolts removed, and that was the only thing holding up removing the engine. B/C we did not want to loose the refrigerant from the AC I did not move the radiator/condenser, and taking the trans out with the engine would be difficult w/o removing the radiator and condenser. Plus the complication of having the driveshaft fixed with rear IS, and the bottom of the car plate over the drive-train made me opt for the quick and dirty. I will swap transmissions for the turbo, not sure what differences are but they are usually sturdier.
A busy day! I should know the Sky very well after doing this project !
ps. I'm removing the engine b/c the body guys said we need to straighten the frame a slight bit and its easier to push and pull, so removing the engine was recommended, and I was going to swap for 2.0 of the other car anyway....