Engine Removal and Installation
REMOVAL PROCEDURE- TOOLS REQUIRED
- J 28467-A Engine Support Fixture
- J 28467-450 Engine Support Fixture Adapter
- J 36857 Lift Brackets
1. Disconnect the negative battery cable.
Caution: Refer to Battery Disconnect Caution in Service Precautions.
2. Drain the coolant.
3. Remove the wiper arms.
4. Remove the air inlet grilles.
5. Remove the hood.
6. Remove the battery.
7. Recover the refrigerant.
8. Disconnect the wiring connectors (1).
Important: Tag all of the wires removed to prevent improper reinstallation.
9. Remove the body ground wire from the negative battery cable end.
10. Siphon the power steering fluid from the power steering reservoir.
11. Remove the power supply wires from the battery positive cable end.
12. Release the power steering suction hose clamp and remove the power steering suction hose.
13. Remove the power steering discharge hose fitting (a crow's foot wrench works best) from the power steering pump.
14. Remove the brake booster threaded vacuum fitting from the intake plenum (1).
15. Remove the vacuum hoses (2) from the brake power booster hose.
Important: Tag all of the vacuum hoses to aid in reassembly.
16. Remove the intake plenum switchover valve electrical connection.
17. Remove the intake plenum switchover valve vacuum hose.
18. Remove the intake plenum switchover valve bolts.
19. Remove the intake plenum switchover valve. (Removal of the valve prevents damage from the lift chain when removing the engine.)
20. Unclip the ECM from the underhood electrical center.
21. Unclip the relays from the electrical center box to enable removal of the entire wiring harness (ECM Included) from the electrical center.
22. Disconnect the large blue and white wiring harness connectors (1).
23. Drape the entire wiring harness over the top of the engine and secure to prevent interference when removing the engine.
24. Remove the accelerator cable retaining clip (3).
25. Remove the accelerator cable (2) from the throttle body.
26. Remove the cruise control cable retaining clip (1).
27. Remove the cruise control cable from the throttle body.
28. Relieve the fuel system pressure.
Important: Counterhold the fuel supply hose connection to prevent damage to the fuel rail. Residual fuel may be present in the supply hose; provide a means to capture fuel if necessary.
29. Disconnect the fuel supply hose connection.
Important: Counterhold the fuel return hose connection to prevent damage to the fuel rail. Residual fuel may be present in the return hose, provide a means to capture fuel if necessary.
30. Disconnect the fuel return hose connection.
31. Release the coolant return hose clamp and remove the hose from the throttle body.
32. Remove the vacuum hose from the purge valve located on top of the engine ventilation chamber. (The engine ventilation chamber is located on the rear, passenger side of the engine.)
33. Remove the vacuum hose from the hot water control valve.
34. Release the coolant reservoir hose clamp and remove the hose from the coolant intake pipe.
Important: Use care with the locking tabs on the quick connects, they break easily.
35. Disconnect the heater hose quick connects from the heater core pipes. (Press the tabs and pull back on the sleeve to unlock, then carefully pull back to remove. It is possible to reach the quick connects through the access cover, near the HVAC pollen filter). Discard the green plastic assembly markers if applicable.
36. Remove the intake air resonator.
37. Remove the radiator.
38. Remove the A/C compressor/condenser (HP) hose bracket screws where the bracket connects near the driver's side frame rail.
39. Reposition the A/C compressor/condenser (HP) hose and bracket to allow for extra clearances when removing the engine.
40. Disconnect the quick-connect near the high pressure service fitting.
41. Disconnect the quick-connect near the low pressure service fitting.
Important: Support the engine whenever the transmission is removed. The engine mounts are silicone filled and do not provide sufficient rigidity to prevent the engine from falling forward or backward with the transmission removed.
42. Install the J 28467-A, the J 28467-450 and the J 36857.
43. Raise and support the vehicle.
44. Remove the splash shield bolts.
45. Remove the splash shield.
46. Disconnect the A/C compressor electrical connector.
47. Remove the transmission.
48. Remove the engine mount nuts.
49. Lower the vehicle.
50. Connect the engine lift chains to the three support lift shackles.
51. Remove the J28467-A Engine Support Fixture after the engine lift has assumed the weight of the engine.
52. Remove the engine. Note the positioning of the motor mount guide pins.
INSTALLATION PROCEDURE
1. Install the engine.
2. After the engine is in place, install the J 28467-A Engine Support Fixture.
3. Remove the engine lift chains from the three support lift shackles.
4. Raise and support the vehicle.
5. Ensure the guide pins (1) are in place and install the engine mount nuts.
- Tighten the lower engine mount nuts to 55 Nm (41 ft lbs).
Notice: Refer to Fastener Notice in Service Precautions.
6. Install the transmission.
7. Install the A/C compressor electrical connector.
8. Install the splash shield.
9. Install the splash shield bolts.
- Tighten the splash shield bolts until fully seated. Do not strip the splash shield bolts.
10. Lower the vehicle.
11. Remove the J 28467-A Engine Support Fixture.
12. Connect the quick-connect near the low pressure service fitting.
13. Connect the quick-connect near the high pressure service fitting.
14. Position the A/C compressor/condenser (HP) hose and bracket.
15. Install the A/C compressor/condenser (HP) hose bracket screws where the bracket connects near the driver's side frame rail.
- Tighten the A/C compressor/condenser hose bracket screws to 8 Nm (71 inch lbs).
16. Install the radiator.
17. Install the intake air resonator.
18. Install the heater hose quick connects to the heater core connections.
Important: Ensure the quick connects are fully seated and that the retaining sleeves are pushed in to the locked position.
19. Install the coolant reservoir hose and clamp to the coolant intake pipe.
20. Install the vacuum hose to the hot water control valve.
21. Install the vacuum hose to the purge valve located on the engine ventilation chamber.
22. Install the coolant return hose and clamp to the throttle body.
23. Install the fuel supply hose.
Important: Counterhold the fuel supply hose connection to prevent damage to the fuel rail.
24. Install the fuel supply hose connection.
- Tighten the fuel supply hose connection to 15 Nm (11 ft lbs).
25. Install the fuel return hose.
Important: Counterhold the fuel return hose connection to prevent damage to the fuel rail.
26. Install the fuel return hose connection.
- Tighten the fuel return hose connection to 15 Nm (11 ft lbs).
27. Install the cruise control cable to the throttle body.
28. Install the cruise control cable retaining clip (1).
29. Install the accelerator cable (2) to the throttle body.
30. Install the accelerator cable retaining clip (3).
31. Install the large blue and white wiring harness connectors (1).
32. Install the wiring harness to the electrical center box and clip the relays in place.
33. Install the ECM and secure in place.
34. Install the intake plenum switch-over valve.
35. Install the intake plenum switch-over valve bolts.
- Tighten the intake plenum switch-over valve bolts to 8 Nm (71 inch lbs).
36. Install the intake plenum switch-over valve vacuum hose.
37. Install the intake plenum switch-over valve electrical connection.
38. Install the vacuum hoses to the brake power booster hose.
39. Install the brake booster threaded vacuum fitting (1) to the intake plenum.
- Tighten the brake booster threaded vacuum fitting until fully seated. Do not strip the brake booster threaded fitting.
40. Install the power steering pump discharge hose to the power steering pump.
- Tighten the power steering pump discharge hose connection to 28 Nm (21 ft lbs).
41. Install the power steering suction hose and clamp.
42. Install the four power supply wires to the battery positive cable end.
43. Install the body ground wire to the battery negative cable end.
44. Connect the large black wiring harness connectors (1).
45. Install the air inlet grilles.
46. Install the wiper arms.
47. Install the hood.
48. Install the battery.
49. Reconnect the negative battery cable.
50. Fill the power steering system.
51. Fill and bleed the cooling system.
52. Reprogram the applicable accessories.
53. Recharge the A/C system.
54. Leak check the A/C system.