Engine Replacement

Engine Replacement

Tools Required

* J 28467-86 Right Engine Lift Bracket
* J 28467-87 Left Engine Lift Bracket

Removal Procedure




Caution: Refer to Battery Disconnect Caution.

1. Drain the engine oil.
2. Remove the powertrain.
3. Remove the left exhaust manifold assembly.
4. Remove the left engine mount bracket.




5. Remove the drive belt tensioner.
6. Remove the generator.




7. Remove the bolt (1) securing the starter/generator harness clip to the front of the engine.




8. Remove the bolts and nut securing the engine wiring harness to the left side of the engine.
9. Remove the right exhaust manifold assembly.
10. Remove the right engine mount bracket.




11. Disconnect the electrical connector (2) from the engine oil level sensor (1).
12. Remove the power steering reservoir.
13. Remove the air conditioning compressor and bracket.




14. Remove the transmission cooler lines.
15. Remove the coolant temperature sensor.




16. Remove the bolts (1) and nut (2) securing the wiring harness to the engine.




17. Remove the engine wiring harness.
18. Remove the throttle body assembly.
19. Remove the left ignition module assembly.
20. Remove the right ignition module assembly.
21. Remove the starter motor from the engine.




22. Disconnect the electrical connector (5) from the left-hand knock sensor.
23. Disconnect the electrical connector (1) from the right-hand knock sensor.
24. Disconnect the electrical connector from the crank sensor (4).
25. Remove the bolt (2) securing the wiring harness (3) to the engine.
26. Remove the driveline support bolts.

Important: Visually inspect the transmission wiring harness to ensure detachment from the engine.

27. Insert a flat-headed screwdriver, or similar tool, between the driveline support and the flywheel housing, then separate the driveline assembly from the engine.
28. Slowly pull the driveline support assembly away from the engine.
29. Install the J 28467-86 and J 28467-87 to the engine.
30. Install an engine hoist to the J 41798.
31. Remove the flywheel housing bolts.
32. Remove the flywheel housing from the engine.
33. Remove the engine from the lift table.
34. Remove the engine hoist.
35. Remove the engine lift brackets.

Installation Procedure

1. Using an engine hoist, install the replacement engine on an engine stand.




2. Install the transmission oil cooler pipes to engine.




3. Connect the harness to the low lever oil switch.





Notice: Refer to Fastener Notice.

4. Install the bolt through the engine harness clip and secure to the right side of the engine.

Tighten the bolts to 35 N.m (26 lb ft).




5. Connect the left rear engine harness ground terminal to the engine.

Tighten the bolt to 12 N.m (106 lb in).




6. Connect the harness to the oil pressure sensor.




7. Install the air conditioning/power steering bracket to the engine assembly.
8. Install the power steering pump reservoir to the engine.
9. Install the drive belt tensioner.




10. Install the generator coolant inlet hose fitting.

Tighten the fitting to 25 N.m (18 lb ft).




11. Install the generator rear brace to the engine.

Tighten the bolt to 50 N.m (37 lb ft).

12. Install the generator stud to the engine lower crankcase.

Tighten the stud to 12 N.m (106 lb in).

13. Install the generator.




14. Connect the harness connector (5) to the left knock sensor.
15. Connect the harness connector (1) to the right knock sensor.
16. Connect the harness connector (4) to the crank sensor.
17. Install the bolt (2) through the harness bracket.

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

18. Install the starter.




19. Attach the right side upper wiring harness as shown.




20. Attach the left side upper wiring harness to the cam cover as shown.




21. Connect the engine harness to the right camshaft position sensors.
22. Connect the engine wiring harness to the purge valve solenoid.
23. Connect the engine wiring harness to the left camshaft position sensors.




24. Connect the jumper harness to the engine harness as shown.
25. Install the left ignition module assembly.
26. Install the right ignition module assembly.
27. Install the coolant temperature sensor.




28. Connect the harness to the throttle position sensor.
29. Install the left engine mount bracket to the engine.




30. Secure the wiring harness to the engine.
^ Tighten the bolts (1) to 35 N.m (26 lb ft).
^ Tighten the nut (2) to 35 N.m (26 lb ft).
31. Install the right engine mount bracket to the engine.
32. Install an engine hoist to the engine.
33. Remove the engine from the engine stand.
34. Install the flywheel housing and bolts.




35. Install the flywheel housing left side cover to the engine.




36. Install the engine closeout cover to the right side of the bell housing.

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




37. Install the engine wiring harness to the engine by inserting the bolts through the harness clips and into the bell housing.

Tighten the bolts to 50 N.m (37 lb ft).

38. Install the engine into the front cradle.
39. Remove the engine lift brackets.
40. Install the exhaust manifold studs to the right cylinder head.

Tighten the studs to 6 N.m (53 lb in).

41. Install the exhaust manifold studs to the left cylinder head.

Tighten the studs to 6 N.m (53 lb in).

42. Install the right exhaust manifold assembly to the engine.
43. Install the left exhaust manifold assembly to the engine.
44. Install the evaporator emission canister purge tube assembly to the engine.
45. Install the powertrain.
46. Fill the oil system to the proper level.