Removal and Replacement
REMOVAL1. Perform fuel pressure release procedure. . Remove fuel line to fuel rail.
2. Disconnect battery.
3. Remove air cleaner and hoses.
4. Remove battery cover, battery and battery tray, with integral vacuum reservoir, from vehicle.
5. Block off heater hoses to rear heater assembly, if equipped.
6. Drain cooling system.
7. Disconnect heater hoses.
8. Remove fan module and radiator. Refer to Cooling System for procedure.
9. Disconnect transmission shift linkage.
10. Disconnect throttle body linkage and vacuum hoses from throttle body.
11. Remove accessory drive belts.
12. Remove air conditioning compressor from engine and set it aside.
13. Disconnect generator wiring harness and remove generator.
14. Hoist vehicle and remove right and left inner splash shields.
Fig. 39
16. Remove crossmember cradle plate (Fiat 39).
16. Remove axle shafts. Refer to Transmission and Drivetrain for procedure.
17. AWD equipped: Mark orientation and separate propeller shaft from power transfer unit. Refer to Transmission and Drivetrain for procedure.
18. Disconnect exhaust pipe from manifold.
19. Remove front engine mount and bracket as an assembly.
20. Remove rear transmission mount and bracket.
21. Remove power steering pump and bracket assembly.
22. Remove wiring harness and connectors from front of engine.
23. Remove bending braces and install Special Tool 6912 Adapters on engine.
24. Remove transmission inspection cover and mark flex plate to torque converter.
25. Remove driveplate to torque converter bolts.
26. Lower the vehicle.
27. Remove ground straps to body.
Fig. 40
28. Raise vehicle enough to allow engine dolly Special Tool 6135 and cradle Special Tool 6710 with post Special Tool 6848 and adaptor Special Tool 6909 to be installed under vehicle (Fig. 40).
29. Loosen cradle engine mounts to allow movement for positioning onto engine locating holes on the engine. Lower vehicle and position cradle mounts until the engine is resting on mounts. Tighten mounts to cradle frame. This will keep mounts from moving when removing or installing engine and transmission.
30. Lower vehicle so the weight of ONLY THE ENGINE AND TRANSMISSION is on the cradle.
31. Remove right engine mount assembly and left transmission mount through bolt.
32. Raise vehicle slowly. It may be necessary to move the engine/transmission assembly on the cradle to allow for removal around body flanges.
INSTALLATION
1. Position engine and transmission assembly under vehicle and slowly lower the vehicle over the engine and transmission. It may be necessary to move the engine/transmission assembly with the cradle for clearance around body flanges.
2. Align engine and transmission mounts to attaching points. Install mounting bolts at the right engine and left transmission mounts.
3. Slowly raise vehicle enough to remove the engine dolly and cradle Special Tools 6135, 6710, 6848 and 6909 (Fig. 40).
4. Remove Special Tools 6912 and install bending braces.
5. Lower vehicle. Install generator and wiring harness.
6. Connect wiring harness on the front of the engine.
7. Install Air Conditioning Compressor.
8. Install power steering pump and bracket.
9. Install accessory drive belt.
10. Raise vehicle and install axle shafts. Refer to Transmission and Drivetrain for procedure.
11. Install transmission and engine mount and bracket assemblies.
12. AWD equipped; Install propeller shaft to power transfer unit.
13. Connect exhaust system to manifold. Refer to Exhaust System for procedure and torque specifications.
14. Install crossmember cradle plate (Fig. 39).
15. Install left and right inner splash shields.
16. Connect automatic transmission shifter linkage. Refer to Transmission and Drivetrain for procedures.
17. Lower vehicle and connect fuel line and heater hoses. Remove plugs from rear heater hoses and install, if equipped.
18. Install ground straps. Connect engine and throttle body connections and harnesses.
19. Connect throttle body linkage. .
20. Install radiator, fan module assembly, and radiator hoses. Fill cooling system. Refer to Cooling System for filling procedures.
21. Install battery tray, battery and cover.
22. Install air cleaner and hoses.
23. Install oil filter. Fill engine crankcase with proper oil to correct level.
24. Connect negative cable to battery.
25. Start engine and run until operating temperature is reached.
26. Adjust transmission linkage, if necessary.