Engine Replacement

Engine Replacement

Removal Procedure

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.

2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging.

3. Drain the cooling system. Refer to Cooling System Draining and Filling (GE 47716) Cooling System Draining and Filling (GE 47716)Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill).

4. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement Service and Repair.

5. Remove the air cleaner outlet rear duct. Refer to Air Cleaner Outlet Rear Duct Replacement Air Cleaner Outlet Rear Duct Replacement.

6. Remove the front bumper fascia. Front Bumper Fascia Removal and Installation Front Bumper Fascia Removal and Installation.





7. Remove the Intake Manifold Cover. Refer to Intake Manifold Cover Replacement Intake Manifold Cover Replacement





8. Remove the air conditioning compressor and the condenser hose nut (1) from the refrigerant hose.





9. Remove the air conditioning compressor and the condenser hose bolt (1) from the A/C compressor (2).

10. Remove the air conditioning compressor and the condenser hose (3).





11. Disconnect the fuel feed line (1) and reposition away from the engine. Refer to Plastic Collar Quick Connect Fitting Service Procedures.





12. Disconnect the EVAP hose (1). Refer to Plastic Collar Quick Connect Fitting Service Procedures.

13. Disconnect the power brake booster vacuum pipe (2). Refer to Power Brake Booster Vacuum Pipe Replacement Service and Repair.

14. Disconnect the transmission vent hose (3) from the coolant surge tank.





15. Remove the radiator surge tank hose (1, 2) lay on top of engine.





16. Disconnect the inlet (1) heater core hoses. Refer to Heater Inlet Hose Replacement Heater Inlet Hose Replacement.





17. Disconnect the outlet (1) heater core hoses. Refer to Heater Outlet Hose Replacement Heater Outlet Hose Replacement.





18. Remove the ground strap bolt (1) from the battery cable and reposition the strap (2) aside.

19. Remove the battery tray. Refer to Battery Tray Replacement Battery Tray Replacement.





20. Remove the ground nuts (1) and put the wiring harness (2) aside.

21. Disconnect the electrical connectors from the engine control module (ECM). Refer to Engine Control Module Replacement Service and Repair.

22. Disconnect the wiring harness from the accessory wiring junction block.





23. Disconnect the wiring harness from the junction connector (1).

24. Place the ECM, transmission and the accessory wiring junction block wiring harnesses on the top of the engine assembly.





25. Remove the radiator inlet hose (1). Refer to Radiator Inlet Hose Replacement Radiator Inlet Hose Replacement.





26. Remove the radiator outlet hose (1). Refer to Radiator Outlet Hose Replacement Radiator Outlet Hose Replacement.





27. Disconnect the transmission range selector lever cable terminal (1) from the transmission manual shift lever pin.

28. Press the locking tabs inward in order to release the transmission range selector lever cable (2) from the cable bracket.





29. Remove the oil cooler inlet (1) and outlet (5) hoses from the retainer (2) on the control valve body cover.

30. Remove the transmission fluid cooler inlet hose nut (3) from the transmission.

31. Remove the transmission fluid cooler inlet hose (1) from the transmission.

32. Remove the transmission fluid cooler outlet hose nut (4) from the transmission.

33. Remove the transmission fluid cooler outlet hose (5) from the transmission.

34. Plug and/or cap the hose and transmission to prevent contamination.





35. Remove and DISCARD the lower steering intermediate shaft bolt (1).

36. Install the engine support fixture. Refer to Engine Support Fixture Engine Support Fixture.

37. Remove the starter motor. Refer to Starter Replacement Service and Repair.





38. Mark the relationship of the flywheel to the torque converter for reassembly.

39. Remove the torque converter to flywheel bolts (1).





40. Remove the lower oil pan to transmission lower bolts (1).





Note:
Do Not disconnect the brake hoses from the calipers.

41. Remove the front brake calipers (1) and caliper bolts (2) from the caliper brackets, and then suspend the calipers with mechanics wire to the body.

42. Remove the exhaust system. Refer to Exhaust System Replacement Service and Repair.





43. Remove and DISCARD the stabilizer link nut (1) from the strut assemblies. Refer to Stabilizer Shaft Link Replacement Service and Repair.

44. Disconnect the right wheel drive shaft from the intermediate shaft.





45. Disconnect the front steering knuckles bolts (1) from the strut assemblies. Refer to Steering Knuckle Replacement Service and Repair.

46. Disconnect the electronic power steering connectors from the electronic power steering assembly. Refer to FEP Connectors (Steering Gear) FEP Connectors (Steering Gear).





47. Remove the rear transmission mount bracket to rear mount through bolt (1).





48. Remove the transmission front mount through bolt (1).

49. Using suitable straps or chains, secure the front of vehicle to the hoist arms.

Note:
Use the engine support fixture to slightly raise the powertrain assembly to aid in the removal of the engine and transmission mount bolts.

50. Use the engine support fixture to slightly raise the powertrain assembly to aid in the removal of the engine and transmission mount bolts.





51. Mark the location of the bolts (1) before removing.

52. Remove the right side engine mount bolts (1). Refer to Engine Mount Replacement Engine Mount Replacement.





53. Mark the location of the bolts (1) before removing.

54. Remove the transmission mount bolts (1), left side. Refer to Transmission Mount Replacement - Left Side Transmission Mount Replacement - Left Side.

55. Using a suitable engine support table, lower the vehicle until the drivetrain and front suspension frame contacts the engine support table.

56. Position blocks of wood below the oil pan and transmission to stabilize the powertrain on the support table.

57. Using the engine support fixture, lower the powertrain down until it is resting on the engine support table.

58. Remove the engine support fixture. Refer to Engine Support Fixture Engine Support Fixture.





59. Remove and DISCARD the rear frame reinforcement bolts (1).





60. Remove the rear frame reinforcement bolts (1, 2).





61. Remove the front frame reinforcement bolts (1).

62. Slowly and carefully raise the vehicle, ensure the engine, transmission, radiator assembly and drivetrain suspension frame are free from wiring, hoses and other engine compartment components.

63. Disconnect engine coolant hoses as necessary.

64. Disconnect electrical connectors as necessary.





65. Remove the lower cylinder head to transmission lower bolts (1, 2).





66. Remove the lower engine case to transmission lower bolts (1).





67. Remove the upper transmission to engine bolts (1) and separate the engine and transmission.

68. Install the engine to the engine stand.

69. Transfer parts as needed.

Installation Procedure





1. Remove the engine from the engine stand.

2. Install the transmission to the engine.

Caution:
Refer to Fastener Caution Fastener Caution.

3. Install the upper transmission to engine bolts (1) and tighten to 75 Nm (55 lb ft).





4. Install the lower engine case to transmission lower bolts (1) and tighten to 75 Nm (55 lb ft).





5. Install the lower cylinder head to transmission lower bolts (1, 2) and tighten to 75 Nm (55 lb ft).

6. Position the engine, transmission, radiator assembly and drivetrain suspension frame under the vehicle.

7. Slowly and carefully lower the vehicle, ensure the engine, transmission, radiator assembly and drivetrain suspension frame are free from wiring, hoses and other engine compartment components.





8. Install the front frame reinforcement bolts (1) and tighten to 160 Nm (118 lb ft).





9. Install the rear frame reinforcement bolts (1, 2) and tighten to 160 Nm (118 lb ft).





10. Install NEW rear frame reinforcement bolts (1) and tighten to 60 Nm (44 lb ft) plus 45 degrees.

11. Install the engine support fixture. Refer to Engine Support Fixture Engine Support Fixture.





12. Install the transmission bracket mount to mount through bolt (1) and tighten to 100 Nm (74 lb ft).





13. Install the transmission mount through bolt (1) and tighten to 58 Nm (43 lb ft).

Warning:
Refer to Torque-to-Yield Fastener Warning Torque-to-Yield Fastener Warning.


14. Install the NEW left transmission mount to transmission bolts (1) and tighten to 50 Nm (37 lb ft) plus 60-75 degrees.





15. Install the right side engine mount bolts (1) and tighten to 50 Nm (37 lb ft) plus 70 degrees.





16. Install the NEW lower steering intermediate shaft (1) bolt and tighten to 34 Nm (25 lb ft).

17. Connect the electronic power steering connectors to the electronic power steering assembly. Refer to FEP Connectors (Steering Gear) FEP Connectors (Steering Gear).





18. Connect the front steering knuckles bolts (1) to the strut assemblies. Refer to Steering Knuckle Replacement Service and Repair.





19. Install the NEW the stabilizer link nut (1) to the strut assemblies. Refer to Stabilizer Shaft Link Replacement Service and Repair.

20. Connect the right wheel drive shaft from the intermediate shaft.





21. Install the front brake caliper (1) and tighten the brake caliper guide pin bolt (2) to 28 Nm (21 lb ft).

22. Install the exhaust system. Refer to Exhaust System Replacement Service and Repair.

23. Connect the wheel speed connectors to the steering knuckles.





24. Install the lower oil pan to transmission lower bolts (1). and tighten to 75 Nm (55 lb ft).





25. Install the torque converter to flywheel bolts (1) and tighten to 62 Nm (46 lb ft).

26. Install the starter. Refer to Starter Replacement Service and Repair.

27. Lower the vehicle.

28. Remove the engine support fixture.





29. Install the transmission fluid cooler outlet hose (5) to the transmission.

30. Install the transmission fluid cooler outlet hose retainer nut (4) and tighten to 22 Nm (16 lb ft).

31. Install the transmission fluid cooler inlet hose (1) to the transmission.

32. Install the transmission fluid cooler inlet hose retainer nut (3).

33. Install the oil cooler inlet (1) and outlet (5) hoses to the retainer (2) on the control valve body cover.





34. Connect the range selector cable (2) to the range selector cable bracket.

35. Connect the range selector cable end (1) to the range selector lever.





36. Install the radiator inlet hose (1). Refer to Radiator Inlet Hose Replacement Radiator Inlet Hose Replacement.

37. Install the radiator outlet hose (1). Refer to Radiator Outlet Hose Replacement Radiator Outlet Hose Replacement.





38. Install the wiring harnesses (2).

39. Install the ground nuts (1) and tighten to 9 Nm (80 lb in).

40. Connect the wiring connectors and ground strap to the transmission.

41. Install the battery tray. Refer to Battery Tray Replacement Battery Tray Replacement

42. Connect the wiring harness to the accessory wiring junction block.





43. Connect the wiring harness plugs (1).





44. Connect the outlet (1) heater core hoses. Refer to Heater Outlet Hose Replacement Heater Outlet Hose Replacement.





45. Connect the inlet (1) heater core hoses. Refer to Heater Inlet Hose Replacement Heater Inlet Hose Replacement.





46. Connect the coolant hose (2, 1) to radiator surge tank.





47. Connect the EVAP hose (1). Refer to Plastic Collar Quick Connect Fitting Service Procedures.

48. Connect the power brake booster vacuum pipe (2). Refer to Power Brake Booster Vacuum Pipe Replacement Service and Repair.

49. Connect the transmission vent hose (3) from the coolant surge tank.





50. Connect the fuel feed line (1) to the engine. Refer to Plastic Collar Quick Connect Fitting Service Procedures.





Note:
Use NEW O-ring seals. Refer to Air Conditioning O-Ring Seal Replacement Service and Repair.

51. Install the air conditioning compressor and the condenser hose (3).

52. Install the air conditioning compressor and the condenser hose bolt (1) to the A/C compressor (2) and tighten to 22 Nm (16 lb ft).





53. Install the air conditioning compressor and the condenser hose nut (3) to the A/C condenser (4) and tighten to 22 Nm (16 lb ft).

54. Install the air conditioning compressor and the condenser hose nut (1) to the refrigerant hose (2) and tighten to 22 Nm (16 lb ft).

55. Install the front bumper fascia. Refer to Front Bumper Fascia Removal and Installation Front Bumper Fascia Removal and Installation.

56. Install the air cleaner outlet rear duct. Refer to Air Cleaner Outlet Rear Duct Replacement Air Cleaner Outlet Rear Duct Replacement.

57. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement Service and Repair.

58. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging.

59. Fill the engine cooling system. Refer to Cooling System Draining and Filling (GE 47716) Cooling System Draining and Filling (GE 47716)Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill).





60. Install the Intake Manifold Cover. Refer to Intake Manifold Cover Replacement Intake Manifold Cover Replacement.

61. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection Battery Negative Cable Disconnection and Connection.