Removal and Replacement

Engine Replacement

^ Tools Required
- J 41798 Engine Lifting Brackets
- J 21366 Converter Holding Strap
- J 38185 Hose Clamp Pliers

Removal Procedure





1. Remove the hood.
2. Place fender covers over both fenders.
3. Disconnect the negative battery cable.
4. Recover the refrigerant.
5. Remove the radiator.
6. Remove the radiator support brace.
7. Remove the front differential drive axle, if equipped with 4-wheel drive (4WD).
8. Remove the wheel drive shafts.
9. Remove the intake manifold.
10. Disconnect the following electrical connectors:
^ Oil pressure sensor (1)
^ Oxygen sensors (2, 3)
^ Camshaft position (CMP) sensor (4)





11. Remove the air conditioning (A/C) compressor hose.
12. Disconnect the rear auxiliary A/C compressor pipe fitting (7).
13. Remove the rear auxiliary A/C compressor pipe nut and bolt (2, 5).
14. Tie the pipe assembly out of the way.





15. Disconnect the engine coolant temperature (ECT) sensor (1).
16. Remove the ground terminal bolt (2).
17. Remove the retaining clips from the brackets.





18. Disconnect the A/C pressure switch electrical connector (2).
19. Remove the retaining clip (1) from the cylinder head.
20. Raise and suitably support the vehicle. Refer to Vehicle Lifting.





21. Remove the ground terminal bolts (2, 4).
22. Remove the starter.





23. Remove the battery cable channel bolt.
24. Remove the battery cable channel from the oil pan.





25. Disconnect the A/C compressor electrical connector.
26. Lower the vehicle.
27. Gather all branches of the engine wiring harness and reposition the harness off to the side.





28. Remove the generator cable from the generator. Perform the following:
^ Slide the boot down revealing the terminal stud.
^ Remove the generator cable nut from the terminal stud.
^ Remove the generator cable.





29. Remove the generator bracket bolts.
30. Position the bracket with generator aside.





31. Using J 38185, reposition the inlet hose clamp.
32. Remove the inlet hose from the water outlet.





33. Using J 38185, reposition the inlet hose clamp.
34. Remove the outlet hose from the water outlet.





35. Disconnect the auxiliary heater inlet and outlet hose/pipe assembly from the heater water shutoff valve pipes.





36. Using J 38185, reposition the auxiliary heater inlet and outlet hose clamps.
37. Remove the auxiliary heater inlet and outlet hoses/pipes from the water pump.





38. Remove the ignition coils as required for the proper fit of J 41798 before lifting the engine.

39. Notice: Refer to Fastener Notice in Service Precautions.

Install J 41798 to the cylinder heads.
^ Tighten the M8 bolts to 25 Nm (18 ft. lbs.).
^ Tighten the M10 bolts to 50 Nm (37 ft. lbs.).
40. Raise the vehicle.
41. Remove the catalytic converter.





42. Remove the 3 bracket bolts from both the right and the left sides of the frame engine mount.





43. Remove the torque converter bolts.





44. Remove the transmission oil level indicator tube nut.





45. Remove the transmission oil level indicator tube.





46. Remove the transmission bolt and stud on the right side.





47. Remove the lower transmission bolt/studs.
48. Lower the vehicle.
49. Remove the 3 upper transmission bolts/studs.
50. Install an engine hoist to J 41798.
51. Install a floor jack under the transmission for support.
52. Separate the engine from the transmission.
53. Remove the engine.
54. Install the engine to an engine stand.
55. Install J 21366 to the transmission in order to hold the torque converter.

Installation Procedure





1. Remove J 21366 from the transmission.
2. Install an engine hoist to J 41798.
3. Remove the engine from the engine stand.
4. Install the engine.
5. Mate the engine to the transmission.
6. Remove the floor jack from under the transmission for support.
7. Install the 3 upper transmission bolts/studs.
Tighten the bolts/studs to 50 Nm (37 ft. lbs.).
8. Raise the vehicle.
9. Install the lower transmission bolt/studs.
Tighten the bolts/studs to 50 Nm (37 ft. lbs.).





10. Install the transmission bolt and stud on the right side.
Tighten the bolts/studs to 50 Nm (37 ft. lbs.).





11. Install the transmission oil level indicator tube.





12. Install the transmission oil level indicator tube nut.
Tighten the nut to 10 Nm (89 ft. lbs.).





13. Install the torque converter bolts.
Tighten the bolts to 60 Nm (44 ft. lbs.).





14. Install the 3 bracket bolts to both the right and the left sides of the frame engine mount.
Tighten the bolts to 50 Nm (37 ft. lbs.).
15. Install the catalytic converter.
16. Lower the vehicle.





17. Remove J 41798 from the cylinder heads.
18. Install the ignition coil(s) (as required).
Tighten the bolts to 8 Nm (71 inch lbs.).





19. Install the auxiliary heater inlet and outlet hoses/pipes to the water pump.
20. Using J 38185, reposition the auxiliary heater inlet and outlet hose clamps.





21. Connect the auxiliary heater inlet and outlet hose/pipe assembly to the heater water shutoff valve pipes.





22. Install the outlet hose to the water outlet.
23. Using J 38185, reposition the inlet hose clamp.





24. Install the inlet hose to the water outlet.
25. Using J 38185, reposition the inlet hose clamp.





26. Position the bracket with generator to the engine.
27. Install the generator bracket bolts.
Tighten the bolts to 50 Nm (37 ft. lbs.).





28. Install the generator cable to the generator, perform the following procedure:
^ Install the generator cable.
^ Install the generator cable nut to the terminal stud.
Tighten the nut to 9 Nm (80 inch lbs.).
^ Slide the boot down covering the terminal stud.





29. Gather all branches of the engine wiring harness and position the harness over the engine.
30. Raise the vehicle.
31. Connect the A/C compressor electrical connector.





32. Install the battery cable channel to the oil pan.
33. Install the battery cable channel bolt.
Tighten the bolt to 12 Nm (106 inch lbs.).





34. Install the starter.
35. Install the ground terminal bolts (2, 4).
Tighten the bolt to 25 Nm (18 ft. lbs.).
36. Lower the vehicle.





37. Install the retaining clip (1) to the cylinder head.
38. Connect the A/C pressure switch electrical connector (2).





39. Install the retaining clips to the brackets.
40. Install the ground terminal bolt (2).
Tighten the bolt to 25 Nm (18 ft. lbs.).
41. Connect the ECT sensor (1).





42. Install the rear auxiliary A/C compressor pipe nut and bolt (2, 5).
Tighten the nut/bolt to 20 Nm (15 ft. lbs.).
43. Connect the rear auxiliary A/C compressor pipe fitting (7).
Tighten the nut to 16 Nm (12 ft. lbs.).
44. Install the A/C compressor hose.





45. Connect the following electrical connectors:
^ Oil pressure sensor (1)
^ Oxygen sensors (2, 3)
^ Camshaft position (CMP) sensor (4)
46. Install the intake manifold.
47. Install the wheel drive shafts.
48. Install the front differential drive axle, if equipped with 4WD.
49. Install the radiator support brace.
50. Install the radiator.
51. Recharge the refrigerant.
52. Connect the negative battery cable.
53. Remove the fender covers from both fenders.
54. Prelube the engine.
55. Perform the CKP system variation learn procedure.
56. Install the hood.

Important: After an overhaul, the engine should be tested. Use the following procedure after the engine is installed in the vehicle.

57. Test the vehicle using the following procedure:
1. Disable the ignition system.
2. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
3. Enable the ignition system.
4. Start the engine and listen for unusual noises.
5. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
6. Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.
7. Listen for sticking lifter and other unusual noises.
8. Inspect for fuel, oil and/or coolant leaks while the engine is running.
9. Close the hood.