Removal and Replacement

REMOVAL - ENGINE ASSEMBLY





NOTE: Capture and store any residual fluid drain age, or leakage from ancillary components, in the appropriately marked containers.

1. Perform the fuel pressure release procedure.
2. Center and secure the steering wheel.
3. Disconnect negative battery cable.
4. Evacuate the air conditioning system.
5. Remove the hood.
6. Remove the windshield cowl assembly.
7. Raise and support the vehicle.
8. Remove the lower engine close out panel.
9. Drain the cooling system.
10. Disconnect the lower radiator hose (2).





11. Remove the front drive axles and housing (if equipped with AWD).





12. Disconnect the generator electrical connectors.
13. Separate the steering column coupling (1) from the steering gear (3).





14. Remove the starter and spacer plate.
15. Disconnect the oil cooler hose at the oil cooler (3) and remove the cooler hose retainer at the transmission.
16. Disconnect the transmission line bracket at the A/C compressor and allow the bolt to rest on the cradle.





17. Disconnect the ground strap (3) at the right transmission housing.
18. Disconnect the engine block heater wiring connector (4) and set aside (if equipped).
19. Remove the crankshaft position sensor.





20. Disconnect the left #2 oxygen senor (3) electrical connector and separate the exhaust manifold from the left exhaust pipe (2).





21. Disconnect the right #2 oxygen senor (2) electrical connector and separate the exhaust manifold from the right exhaust pipe (1).





22. Remove the flex plate inspection cover and torque converter bolts (3).





23. Remove the transmission housing to engine mounting bolts (2) accessible.
24. Remove the engine mounting to cradle fasteners.





25. Lower the vehicle.
26. Remove the upper intake manifold.
27. Disconnect the heater hose (2) and coolant reservoir hose (3) from the rear coolant pipe (1).





28. Disconnect the oxygen sensor connector and the ground wire on the left cylinder head cover.
29. Disconnect the coolant temperature, cam position, oil pressure sensor electrical connectors.
30. Disconnect the left ignition coil (2) and fuel injector harness connectors and position the wiring harness (3) aside





31. Remove the right intake manifold support braces.
32. Disconnect the capacitor and ground strap from the right cylinder head cover.
33. Disconnect the oxygen sensor, knock, EGR, injector and ignition coil harness connectors and position the wiring harness aside.
34. Disconnect the engine wiring harness from the transmission housing and remove the remaining transmission housing bolts.





35. Connect the engine lifting bracket (2) from special tool kit 8534B to the right rear of the cylinder head outer most bolt access hole (5).
36. Install a bolt into the inner most bolt access hole (5) next to the engine lift bracket to assure lifting bracket positioning.





37. Connect a engine hoisting chain (1) to the left timing chain cover (2) engine lifting point and engine lift bracket.

CAUTION: While slowly separating the engine from the vehicle, constant checks must be made to assure proper positioning and that no damage to other components or wiring harnesses occur during separation.

NOTE: As the engine is hoisted from the engine bay area, remove the loosened A/C compressor bolt retaining the transmission cooler lines and direct the lines aside.

38. Carefully remove the engine from the engine bay area.

INSTALLATION - ENGINE ASSEMBLY

CAUTION: Care must be taken when installing the engine to prevent pinching the power steering rack sensor with the left engine mount.





1. Install special tool #8534B, engine lifting bracket (2) to the right rear of the cylinder head and install a bolt into the inner most bolt hole (5) next to the bracket (5).





2. Connect a engine hoisting chain (1) to the left timing chain cover (2) lifting point and the engine lifting bracket.





CAUTION: Care must be taken when installing the engine to prevent pinching the power steering rack sensor with the left engine mount. Constantly check to assure proper positioning and no damage occurs to other components or harnesses until union is made.

NOTE: As the engine is lowered into the engine bay area, install and hand tighten the A/C compressor bolt retaining the transmission cooler lines.

3. Carefully install the engine into the engine bay area and complete the union with the transmission.
4. Properly route the engine wiring harness behind the engine and tighten the accessible transmission bolts to 68 Nm (50 ft. lbs.).





5. Properly position the right engine harness (4) and connect the oxygen sensor, knock sensor, EGR, fuel injector and ignition coil harness connectors.
6. Connect the capacitor (3) and ground strap (3) to the right cylinder head cover.
7. Install the right intake manifold support braces.





8. Properly position the left engine harness (3) and connect the ignition coil (2) and fuel injector harness connectors.
9. Connect the coolant temperature, cam position, oil pressure sensor harness connectors.
10. Connect the oxygen sensor, and the ground wire, to the left cylinder head cover.





11. Connect the heater hose (2) and coolant reservoir hose (3) to the rear coolant pipe (1).
12. Install the upper intake manifold.
13. Connect the upper radiator hose.





14. Raise and support the vehicle.
15. Install the engine mounting nuts and tighten to 101 Nm (75 ft. lbs.).
16. Install the remaining transmission housing bolts and tighten to 68 Nm (50 ft. lbs.).





17. Install the torque converter bolts (3). Tighten bolts to 75 Nm (55 ft. lbs.).
18. Install the torque converter inspection cover. Tighten bolts to 12 Nm (105 inch lbs.)





19. Connect the right exhaust pipe to the exhaust manifold (1) and connect the oxygen sensor (2).





20. Install the front drive axle housing and front axle shafts (if equipped with AWD).





21. Connect the left exhaust pipe to the exhaust manifold (2) and connect the oxygen sensor (3)
22. Install the crankshaft position sensor.





23. Connect the engine block heater (4) (if equipped).
24. Connect the ground strap (3) at the right transmission housing.





25. Tighten the transmission line bracket at the A/C compressor.
26. Connect the oil cooler hose at the cooler (3) and secure the cooler hose retainer at the transmission.
27. Connect the lower radiator hose (2).
28. Install the starter and spacer plate.





29. Align and connect the steering column coupler (1) to the steering gear (3).
30. Connect the generator electrical connectors.
31. Install new oil filter.
32. Install the lower engine close out panel.
33. Lower the vehicle.
34. Fill the cooling system to the proper level using the appropriate coolant.
35. Fill engine crankcase with proper oil to correct level.
36. Evacuate and recharge air conditioning.
37. Install the windshield wiper cowl assembly
38. Install the hood.
39. Connect the negative battery cable.
40. Start engine and run until operating temperature is reached and radiator fans cycle.
41. Check all fluid levels and properly fill.