Removal and Replacement

REMOVAL
1. Disconnect the battery negative cable.
2. Drain cooling system. Refer to Cooling System for the proper procedure.
3. Recover refrigerant from A/C system, if equipped. Refer to Heating and Air Conditioning for service procedures.
4. Remove the A/C condenser, if equipped.
5. Remove the transmission oil cooler. Refer to Transmission and Drivetrain for the correct procedure.
6. Remove the washer bottle from the fan shroud.
7. Remove the viscous fan/drive. Refer to Cooling System for the correct procedure.
8. Remove radiator. Refer to Cooling System for the correct procedure.
9. Remove the upper crossmember and top core support.
10. Remove the accessory drive belt. Refer to Drive Belts, Mounts, Brackets and Accessories.
11. Remove the A/C compressor with the lines attached. Secure compressor out of the way.
12. Remove generator assembly. (refer to Starting and Charging).
13. Remove the air cleaner resonator and duct work as an assembly.
14. Disconnect the throttle linkage.
15. Remove throttle body.
16. Remove the intake manifold.
17. Remove the distributor cap and wiring.
18. Disconnect the heater hoses.
19. Disconnect the power steering hoses, if equipped.
20. Perform the Fuel System Pressure Release procedure. Refer to Powertrain Management.
21. Disconnect the fuel supply line. Refer to Powertrain Managements for the correct procedure..
22. On Manual Transmission vehicles, remove the shift lever (refer to Transmissions and Drivetrain).
23. Raise and support the vehicle on a hoist and drain the engine oil.
24. Remove engine front mount thru-bolt nuts.
25. Disconnect the transmission oil cooler lines from their retainers at the oil pan bolts.
26. Disconnect exhaust pipe at manifolds.
27. Disconnect the starter wires. Remove starter motor (refer to Starting and Charging).
28. Remove the dust shield and transmission inspection cover.
29. Remove drive plate to converter bolts (Automatic transmission equipped vehicles).
30. Remove transmission bell housing to engine block bolts.
31. Lower the vehicle.
32. Install an engine lifting fixture.
33. Separate engine from transmission, 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 engine lifting device.
3. Lower engine into compartment and align engine with transmission:
- Manual Transmission: Align clutch disc assembly (if disturbed). Install transmission input shaft into clutch disc while mating engine and transmission surfaces. Install two transmission to engine block mounting bolts finger tight.
- Automatic Transmission: Mate engine and transmission and install two transmission to engine block mounting bolts finger tight.
4. Lower engine assembly until engine mount through bolts rest in mount perches.
5. Install remaining transmission to engine block mounting bolts and tighten.
6. Tighten engine mount through bolts.
7. Install drive plate to torque converter bolts. (Automatic transmission models)
8. Install the dust shield and transmission cover.
9. Install the starter and connect the starter wires (refer to Starting and Charging).
10. Install exhaust pipe to manifold.
11. Install the transmission cooler line brackets to the oil pan.
12. Install the drain plug and tighten to 34 Nm (25 ft. lbs.) torque.
13. Lower the vehicle.
14. Remove engine lifting fixture.
15. On Manual Transmission vehicles, install the shift lever (refer to Transmissions and Drivetrain).
16. Connect the fuel supply line.
17. Connect the power steering hoses, if equipped.
18. Connect the heater hoses.
19. Install the distributor cap and wiring.
20. Install the intake manifold.
21. Using a new gasket, install throttle body. Tighten the throttle body bolts to 23 Nm (200 in. lbs.) torque.
22. Connect the throttle linkage.
23. Install the air cleaner resonator and duct work.
24. Install the generator and wire connections (refer to Starting and Charging).
25. Install A/C compressor and lines.
26. Install the accessory drive belt (refer to Drive Belts, Mounts, Brackets and Accessories).
27. Install upper radiator support crossmember.
28. Install radiator.
29. Connect the radiator lower hose.
30. Connect the transmission oil cooler lines to the radiator.
31. Install the fan shroud.
32. Install the fan.
33. Connect the radiator upper hose.
34. Install the washer bottle.
35. Install the transmission oil cooler.
36. Connect the transmission cooler lines.
37. If equipped, install the condenser.
38. Evacuate and charge the air conditioning system, if equipped (refer to Heating and Air Conditioning for service procedures).
39. Add engine oil to crankcase.
40. Add coolant to the cooling system (refer to Cooling System for the proper procedure).
41. Connect battery negative cable.
42. Start engine and inspect for leaks.
43. Road test vehicle.