Removal and Replacement

Engine Replacement

Removal Procedure





1. Disconnect the negative battery cable.
2. Remove the hood.
3. Remove the wiper arms.
4. Remove the air inlet grilles.
5. Recover the refrigerant.
6. Drain the cooling system.
7. Remove the intake air resonator electrical connector wiring harness from the radiator outlet hose.
8. Remove the intake air resonator.
9. Remove the AIR pipe.

Important: Tag all of the wires removed to prevent improper reinstallation.

10. Disconnect the large wiring harness connectors.
11. Unclip the ECM from the underhood electrical center.
12. Unclip the relays from the electrical center box to enable removal of the entire wiring harness (ECM included) from the electrical center.
13. Remove the body ground wire from the negative battery cable end.
14. Remove the 4 power supply wires from the battery positive cable end.
15. Drape the entire wiring harness over the top of the engine and secure to prevent interference when removing the engine.
16. Remove the engine cooling fan.
17. Siphon the power steering fluid from the power steering reservoir.





18. Release the power steering suction hose clamp and remove the power steering suction hose from the reservoir.





19. Remove the power steering hose from the power steering pump.

Important: Tag all of the vacuum hoses to aid in reassembly.





20. Remove the brake booster threaded vacuum fitting from the intake plenum (1).
21. Remove the vacuum hoses (2) from the brake power booster hose.
22. Relieve the fuel system pressure.

Notice: Counterhold the fuel supply and return hoses to prevent damage to the fuel rail.

Important: Residual fuel may be present in the supply hose, provide a means to capture fuel if necessary.

23. Remove the fuel supply and return hose from the intake manifold.
24. Release the throttle body coolant hose clamp and remove the hose from the throttle body.
25. 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).





26. Remove the vacuum hose from the hot water control valve.
27. Release the coolant reservoir hose clamp and remove the hose from the coolant intake pipe.
28. Remove the electric heater water pump screws from the right side of the engine compartment.
29. Drape the electric heater water pump (with hoses still attached) over the top of the engine and secure.

Important: Use care with the locking tabs on the quick connects, they break easily.





30. Disconnect the heater hose quick connects from the heater core pipes.
30.1. Raise the air inlet screen on the passenger side and open the access door near the pollen filter.
30.2. Squeeze the tabs on the locking collar and pull back on the sleeve to unlock.
30.3. Carefully pull back on the tabs to remove the quick connect from the heater core pipes.
30.4. Discard the green assembly markers (1) if attached.
31. Remove the A/C compressor/condenser (high pressure) hose bracket screws where the bracket connects near the driver's side frame rail.





32. Remove the condenser line bolt from the condenser.
33. Remove the condenser high pressure line from the condenser and plug the connections to prevent A/C system contamination.
34. Raise and support the vehicle. Refer to Vehicle Lifting.
35. Remove the 4 engine splash shield bolts.
36. Remove the engine splash shield.
37. Drain the engine oil.
38. Remove the A/C compressor.
39. Remove the transmission.





40. Remove the engine mount nuts. Note the orientation of the locator tab (1).
41. Lower the vehicle.
42. Remove the evaporator line bolt from the block fitting.
43. Remove the high pressure A/C line from the evaporator.
44. Remove the high pressure A/C line from the vehicle.
45. Install the engine lifting device to the engine.
46. Remove the engine with assistance.
47. Transfer parts as necessary.

Installation Procedure

Notice: Refer to Fastener Notice in Service Precautions.

1. Install the motor mounts to the engine brackets, if removed.
Tighten the upper motor mount nuts to 40 Nm (30 ft. lbs.).
2. Install the engine with assistance.
3. Remove the engine lift from the engine.
4. Install the high pressure A/C line to the vehicle.
5. Install the high pressure A/C line to the evaporator.
6. Install the evaporator line bolt to the block fitting.
Tighten the evaporator line bolt to 27 Nm (20 ft. lbs.).
7. Raise the vehicle.





Important: Ensure the guide pins (1) are in place and install the engine mount nuts.

8. Install the lower engine mount nuts.
Tighten the lower engine mount nuts to 55 Nm (41 ft. lbs.).
9. Install the transmission.
10. Install the A/C compressor.
11. Install the engine splash shield.
12. Install the 4 engine splash shield bolts.
Tighten the engine splash shield bolts to 10 Nm (89 inch lbs.).
13. Lower the vehicle.





14. Install the A/C system high pressure condenser line to the condenser:
14.1. Remove the plugs from the fittings.
14.2. Clean the fittings and the surrounding areas.
14.3. Install new O-rings.
14.4. Lubricate the O-rings with mineral oil, 525 viscosity.
14.5. Install the condenser line into the condenser.
15. Install the condenser line bolt.
Tighten the condenser line bolt to 27 Nm (20 ft. lbs.).
16. Reposition the A/C compressor/condenser high pressure hose and bracket.
17. Install the A/C compressor/condenser high pressure 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.).

Important: Ensure the quick connects are fully seated and that the retaining sleeves are pushed in to the locked position.





18. Install the heater hose quick connects to the heater core pipes:
18.1. Discard the green assembly marker (1), if not attached to the quick connect.
18.2. Press the quick connects onto the heater core pipes.
18.3. Inspect that the quick connects are fully seated.
18.4. Squeeze the locking tabs (2) and push the retaining sleeve (3) into the locked position.
18.5. Close and secure the access door near the pollen filter.
18.6. Lower the air inlet screen.
19. Install the electric heater water pump (with the hoses attached) to the right side of the engine compartment.
Tighten the electric heater water pump screws until fully seated and not stripped.
20. Install the coolant reservoir hose and clamp to the coolant intake pipe.





21. Install the vacuum hose to the hot water control valve.
22. Install the vacuum hose to the purge valve located on the engine ventilation chamber.
23. Install the coolant hose and clamp to the throttle body.

Notice: Counterhold the hoses, while tightening, to prevent damage to the fuel rail.

24. Install the fuel supply and the fuel return hose to the intake manifold.
Tighten the fuel supply and the fuel return hose to 15 Nm (11 ft. lbs.).





25. Install the vacuum hoses (2) to the brake power booster hose.
26. 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.





27. 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.).





28. Install the power steering suction hose and clamp.
29. Install the cooling fan.
30. Reposition the engine wiring harness to the engine.





31. Install the four power supply wires to the battery positive cable end.
32. Install the body ground wire to the battery negative cable end.
33. Install the wiring harness to the electrical center box and clip the relays in place.
34. Install the ECM and secure in place.
35. Connect the large wiring harness connectors.
36. Install the AIR pipe.
37. Install the air intake resonator.
38. Install the intake air resonator electrical connector wiring harness to the radiator outlet hose.
39. Install the air inlet grilles.
40. Install the wiper arms.
41. Install the hood.
42. Fill the power steering system.
43. Fill the crankcase with engine oil.
44. Connect the negative battery cable.
45. Recharge the A/C system.
46. Fill the cooling system.
47. Bleed the power steering system.
48. Inspect for fluid and exhaust leaks.