Removal and Installation

REMOVAL
1. Remove the battery.
2. Drain cooling system (Refer to Cooling System, for the proper procedure).
3. Discharge the air conditioning system, if equipped (refer to Heating and Air Conditioning for service procedures).
4. Remove the upper crossmember.
5. Remove the transmission oil cooler.
6. Remove the serpentine belt.
7. Remove the A/C, compressor with the lines attached. Set aside.
8. If equipped, remove the condenser.
9. Remove the washer bottle.
10. Disconnect the top radiator hose.
11. Remove the fan.
12. Remove the fan shroud.
13. Disconnect the lower radiator hose.
14. Disconnect the transmission cooler lines.
15. Remove radiator (Refer to Cooling System,).
16. Remove the generator with the wire connections.
17. Remove the air cleaner.
18. Disconnect the throttle linkage.
19. Remove throttle body.
20. Remove the upper intake manifold (refer to Exhaust System and Intake Manifold).
21. Remove the coil assemblies with the ignition cables.
22. Disconnect the heater hoses.
23. Disconnect the power steering hoses, if equipped.
24. Perform the Fuel System Pressure release procedure (refer to Powertrain Management). Disconnect the fuel line.
25. On Manual Transmission vehicles, remove the shift lever (refer to Transmissions and Drivetrain).
26. Raise and support the vehicle on a hoist.
27. Remove the drain plug and drain the engine oil.
28. Loosen front engine mount thru-bolt nuts.
29. Remove the transmission cooler line brackets from oil pan.
30. Disconnect exhaust pipe at manifold (refer to Exhaust System).
31. Disconnect the starter wires. Remove starter motor.
32. refer to Transmissions and Drivetrain for transmission removal.
33. Lower vehicle.

CAUTION: DO NOT lift the engine by the intake manifold.

34. Install an engine lifting fixture.
35. Remove engine from vehicle and install engine assembly on a repair stand.

INSTALLATION
1. Remove engine from the repair stand and position in the engine compartment. Position the thru-bolt into the support cushion brackets.
2. Install an engine support fixture.
3. Raise and support the vehicle on a hoist.
4. refer to Transmissions and Drivetrain for transmission installation.
5. Install the Propeller Shaft.
6. Install the starter and connect the starter wires.
7. Install exhaust pipe to manifold (refer to Exhaust System).
8. Install the transmission cooler line brackets from oil pan.
9. Tighten the Front mount thru-bolt and nuts to 102 Nm (75 ft. lbs.).
10. Install the drain plug and tighten to 34 Nm (25 ft. lbs.) torque.
11. Prime oil pump by squirting oil in the oil filter mounting hole and filling the J-trap of the front timing cover. When oil is running out, install oil filter that has been filled with oil.
12. Lower the vehicle.
13. Remove engine lifting fixture.
14. On Manual Transmission vehicles, install the shift lever (refer to Transmissions and Drivetrain).
15. Connect the fuel lines.
16. Connect the heater hoses.
17. Install the upper intake manifold (refer to Exhaust System).
18. Install the coil assemblies with the ignition cables.
19. Using a new gasket, install throttle body. Tighten the throttle body nuts to 23 Nm (200 inch lbs.) torque.
20. Connect the throttle linkage.
21. Install the air cleaner box.
22. Install the generator and wire connections.
23. Install the upper crossmember.
24. Install radiator (Refer to Cooling System,).
25. Connect the lower radiator hose.
26. Install the transmission oil cooler.
27. Connect the transmission cooler lines.
28. Connect the power steering hoses, if equipped.
29. Install the fan shroud.
30. Install the fan.
31. Connect the top radiator hose.
32. Install the washer bottle.
33. If equipped, install the condenser.
34. Install the A/C compressor with the lines attached.
35. Install the serpentine belt (Refer to Cooling System).
36. Evacuate and charge the air conditioning system, if equipped (refer to Heating and Air Conditioning for service procedures).
37. Add coolant to the cooling system (Refer to Cooling System, for the proper procedure).
38. Install the battery.
39. Warm engine and adjust.
40. Road test vehicle.