Engine Replacement

Engine Replacement

Tools Required
* EN 46114 Engine Lift Brackets
* J 42640 Steering Column Anti-Rotation Pin

Removal Procedure

1. Center the steering wheel.
2. Turn the ignition OFF.




3. Install J 42640 to the steering column.





Important: Do NOT disconnect the battery cables from the engine.

4. Disconnect the negative cable from the battery and the body.
5. Disconnect the positive cable from the battery and the underhood electrical center.
6. Position and secure the battery cables to the engine.
7. Remove the battery.
8. Remove the fuel injector sight shield.




9. Remove the air cleaner duct.




10. Disconnect the cooling fan electrical connectors (2, 3).
11. Remove the cooling fan wiring harnesses (1, 4) from the fan shroud.
12. Secure the wiring harnesses to the vehicle.
13. Drain the cooling system.

Important: Do NOT disconnect the surge hoses from the engine or the radiator.

14. Disconnect the surge tank outlet hose from the surge tank.
15. Position and secure the surge hose to the engine.
16. Disconnect the surge tank inlet hose from the water outlet housing and the radiator.
17. Position and secure the surge tank inlet hose to the vehicle.
18. Disconnect the heater hoses from the heater core.




19. Disconnect the purge line (3) from the purge solenoid.
20. Disconnect the fuel pipe (2) from the fuel rail.
21. Plug the fuel pipe and cap the fuel rail to prevent fuel loss or contamination.
22. Evacuate the air conditioning system. Refer to Refrigerant Recovery and Recharging.
23. Remove the wiper module.

Important: Do NOT disconnect the suction hose from the A/C compressor.

24. Disconnect the air conditioning suction hose from the evaporator and remove the suction hose bracket from the shock tower.
25. Position and secure the suction hose to the engine.

Important: Do NOT disconnect the liquid line from the condenser.

26. Disconnect the air conditioning pressure switch electrical connector and remove the liquid line.
27. Remove the radiator support brackets.




28. Disconnect the brake booster check valve and vacuum hose (1) from the brake booster (2).
29. Position and secure the brake booster hose to the engine.
30. Disconnect the electrical connector to the brake fluid level switch from the master cylinder.
31. Disconnect the electrical connector to the mass air flow sensor.
32. Unlock and disconnect the instrument panel (I/P) electrical connector from the engine located at the rear of the left bank 2 cylinder head.
33. Position and secure the I/P harness to the vehicle.




34. Disconnect the engine module wiring harness connectors (1-3) from the underhood electrical center.
35. Disconnect the wiring harness from the transmission control module (TCM).




36. Remove the ground bolt and wire from the longitudinal rail.




37. Unlock and disconnect the front engine wiring harness electrical connector from the engine control module (ECM).




38. Unlock and disconnect the rear engine wiring harness electrical connector from the ECM.




39. Disconnect the engine harness electrical connector at the longitudinal rail.
40. Position and secure the ground wire, the engine harness and the TCM harness to the engine.





Important: Do NOT disconnect the brake pipes from the master cylinder.

41. Remove the master cylinder nuts.
42. Reposition and secure the master cylinder to the engine.
43. Relieve the fuel system pressure.
44. Raise and support the vehicle. Refer to Vehicle Lifting.
45. Remove the muffler assembly.
46. Remove the propeller shaft.
47. Remove the air deflector.

Important: DO NOT remove the water bottle.

48. Remove the washer bottle bracket.
49. Disconnect the side air baffles from the radiator.
50. Disconnect the left front brake pipe retainer along with the brake pipe from the longitudinal rail.
51. Remove the right front brake pipe from the brake pipe bundle retainer.
52. Disconnect the rear brake pipes from the brake pressure modulator valve (BPMV).
53. Plug the brake pipes and the brake modulator valve in order to minimize brake fluid loss.
54. Remove the front tire and wheel assemblies.
55. Remove the lower intermediate steering shaft.




56. Remove the lower engine mount nuts.




57. Disconnect the transmission shift linkage from the transmission.
58. Disconnect the electrical connector to the low oil level sensor.
Secure the electrical connector and the harness to the engine mount bracket.
59. Remove the headlamp leveling sensors.
60. Secure the shock modules to the lower control arms with a suitable strap in order to prevent damage to the front brake hoses.




61. Remove the upper mounting bolts from the right and left shock module.
62. Raise the vehicle enough to place a suitable lift table under the engine, transmission, front frame and front suspension assembly.
63. Position a suitable powertrain or engine lift table below the frame, engine and transmission.
64. Raise the lift table or lower the vehicle to support the frame, engine and transmission.
65. Remove the bolts which secure the transmission brace to the underbody.




66. Remove the front frame bolts (2).

Important: Ensure that all the hoses, wires, pipes and shock modules clear the vehicle during the removal process.

67. With the aid of an assistant, lower the table or raise the vehicle to remove the engine, transmission, front frame and front suspension assembly from the vehicle.

Important: Do NOT remove the oxygen sensors.

68. Remove the catalytic converters with the oxygen sensors.
69. Remove the thermostat housing with the heater pipes, heater hoses and surge tank outlet hose.
70. Remove the starter motor.
71. Remove the flywheel bolts.




72. Remove the heated oxygen sensor (HO2S) connector bracket (1) from the left cylinder head.
73. Remove the engine wiring harness and related components.
74. Disconnect the transmission oil cooler pipes from the engine, radiator and the transmission.
75. Disconnect the radiator hoses from the water outlet housing and the coolant inlet pipe.
76. Disconnect the power steering cooler hoses from the condenser radiator and fan module (CRFM).
77. Plug the power steering hoses and pipes in order to prevent fluid loss and contamination.
78. Remove the CRFM with the radiator hoses from the frame.
79. Install EN 46114 to the engine.
80. Connect a floor crane to the engine lift brackets and raise the floor crane to partially support the engine.
81. Position a second powertrain lift table below the transmission.
82. Remove the bolts that secure the transmission to the engine.
83. Remove the transmission from the engine.
84. Remove the drive belts.
85. Remove the generator and water pump drive belt tensioner.
86. Remove the A/C compressor and power steering drive belt tensioner.
87. Remove the generator and the generator bracket.
88. Remove the A/C compressor.
89. Remove the power steering pump.
90. Remove the power steering reservoir from the engine.
91. Remove the oil level indicator.
92. Remove the left exhaust manifold.
93. Remove the oil filter adapter.
94. Remove the right exhaust manifold.
95. Remove the crankshaft balancer.
96. Remove the flywheel.
97. Remove the intake manifold.
98. Remove the water outlet.
99. Remove the block heater.
100. Remove the ECM with the ECM bracket.
101. Use a floor crane in order to remove the engine from the frame.
102. Remove the engine mount brackets with the engine mounts.

Installation Procedure

1. Install the engine mount brackets with the engine mounts.
2. Use a floor crane in order to install the engine to the frame.
3. Install the ECM with the ECM bracket.
4. Install the water outlet.
5. Install the block heater.
6. Install the flywheel.
7. Install the intake manifold.
8. Install the crankshaft balancer.
9. Install the right exhaust manifold.
10. Install the oil filter adapter.
11. Install the left exhaust manifold.
12. Install the oil level indicator.
13. Install the generator and the generator bracket.
14. Install the power steering pump.
15. Install the power steering reservoir to the engine.
16. Install the A/C compressor.
17. Install the A/C compressor and power steering drive belt tensioner.
18. Install the generator and water pump drive belt tensioner.
19. Install the drive belts.
20. Install the bolts that secure the transmission to the engine and the flywheel to the torque convertor.
21. Install the starter motor.
22. Remove EN 46114 from the engine.
23. Install the CRFM with the radiator hoses to the frame.
24. Connect the power steering cooler hoses to the CRFM.
25. Connect the radiator hoses to the water outlet housing and the coolant inlet pipe.
26. Install the transmission oil cooler pipes to the engine, radiator and the transmission.
27. Install the engine wiring harness and related components.




28. Install the HO2S connector bracket (1) to the left cylinder head.
29. Install the thermostat housing with the heater pipes, heater hoses and surge tank outlet hose.
30. Install the catalytic converters with the oxygen sensors.
31. Install the fuel lines to the fuel rail and the EVAP purge solenoid.

Important: Ensure that all the hoses, wires, pipes and shock modules clear the vehicle during the installation process.

32. With the aid of an assistant, raise the table or lift the vehicle to install the engine, transmission, front frame and front suspension assembly to the vehicle.




33. Install the front frame bolts (2).
34. Install the transmission support to underbody bolts.
35. Remove the powertrain lift/support table.




36. Install the upper mounting bolts to the right and left shock module.
37. Secure the shock modules to the front frame with mechanics wire to avoid stretching the front brake hoses.
38. Install the headlamp leveling sensors.




39. Connect the transmission shift linkage to the transmission.
40. Connect electrical connector to the low oil level sensor.




41. Install the lower engine mount nuts.
42. Install the lower intermediate steering shaft.
43. Install the front tire and wheel assemblies.
44. Install the front brake pipes and retainers to the underbody.
45. Connect the rear brake pipes to the BPMV.
46. Connect the side air baffles to the radiator.
47. Install the washer bottle bracket.
48. Install the air deflector.
49. Install the propeller shaft.
50. Install the muffler assembly.




51. Install the master cylinder.




52. Connect the engine harness electrical connector at the longitudinal rail.




53. Connect and lock the rear engine wiring harness electrical connector to the ECM.




54. Connect and lock the front engine wiring harness electrical connector to the ECM.





Notice: Refer to Fastener Notice.

55. Install the ground wire and bolt to the longitudinal rail.

Tighten the bolt to 10 N.m (89 lb in).

56. Connect the wiring harness to the transmission control module.




57. Connect the engine module wiring harness connectors (1-3) to the underhood electrical center.
58. Connect and lock the I/P electrical connector to the engine at the rear of the left Bank 2 cylinder head.
59. Connect the mass air flow sensor electrical connector.
60. Connect the electrical connector for the brake fluid level switch from the master cylinder.




61. Connect the brake booster vacuum hose (1) to the brake booster (2).
62. Install the radiator support brackets.




63. Connect the purge line (3) to the purge solenoid.
64. Connect the fuel pipe (2) to the fuel rail.
65. Connect the heater hoses to the heater core.
66. Install the air inlet duct.
67. Position and secure the surge tank inlet hose to the vehicle.
68. Connect the surge tank inlet hose to the water outlet housing and to the radiator.
69. Connect the outlet hose to the surge tank.
70. Connect the electrical connector for the air conditioning pressure switch and the liquid line to the evaporator.
71. Connect the air conditioning suction hose to the evaporator and install the suction hose bracket to the shock tower.




72. Install the air cleaner duct.




73. Install the cooling fan wiring harnesses (1, 4) to the fan shroud.
74. Install the cooling fan electrical connectors (2, 3).
75. Install the wiper module.
76. Install the battery.
77. Install the fuel injector sight shield.



78. Connect the positive cable to the battery and the underhood electrical center.
79. Connect the negative cable from the battery and the body.




80. Remove J 42640 from the steering column.
81. Fill the cooling system.
82. Charge the air conditioning system.
83. Bleed the brake rear circuits.