Removal and Replacement
REMOVAL1. Disconnect battery negative cable.
2. Remove engine cover.
3. Discharge A/C system.
4. Raise vehicle on hoist.
5. Drain cooling system.
6. Drain engine oil. Remove and discard engine oil filter.
7. Disconnect the catalytic converter assembly from the exhaust manifolds.
8. Disconnect the starter motor wires and remove the starter motor.
9. Remove the engine to transmission struts.
10. Remove the inspection cover.
11. Remove the flexplate to converter bolts.
12. Remove the left and right engine mount insulator to mounting bracket nuts.
13. Disconnect the transmission oil cooler lines from the Transmission.
14. Remove the lower transmission to engine mounting bolts.
15. Lower vehicle.
16. Remove grille and mounting bracket (Fig. 4).
17. Remove A/C condenser and immediately cap off open ports/hoses to prevent moisture and particle intrusion.
18. Remove transmission oil cooler (if equipped).
19. Disconnect radiator upper and lower hoses from the radiator.
20. Remove cooling fan shroud from radiator and allow it to rest on viscous fan.
21. Remove cowl plenum to upper radiator support rods.
22. Remove the coolant recovery and windshield washer bottles from the upper radiator support.
23. Remove the PDC from the upper radiator support and secure out of the way.
24. Remove upper radiator support.
25. Remove radiator from engine compartment.
26. Remove fan shroud.
27. Remove accessory drive belt.
28. Remove A/C suction/discharge hose assembly from the compressor (if A/C equipped)
29. Remove the A/C compressor from the vehicle.
30. Remove the power steering pump (Fig. 5).
31. Remove the generator assembly.
32. Disconnect all engine electrical and vacuum connections. Secure the harnesses out of the way for engine removal.
33. Remove the intake manifold.
34. Attach engine lifting device to engine as shown in
35. Raise engine and carefully guide the engine out of the compartment. Vehicle may have to be raised slightly, depending on your equipment.
INSTALLATION
1. Carefully guide engine assembly into the engine compartment.
2. Mate engine and transmission, start two bellhousing to block bolts by hand, and lower engine assembly onto the front mounts.
3. Lower engine and guide engine mounts into frame mounted perches.
4. Remove engine crane and raise vehicle on hoist.
5. Install and tighten all transmission bellhousing to engine block bolts.
6. Tighten engine mount nuts to 102 Nm (75 ft. lbs.).
7. Install catalytic converter w/pipes to manifolds and tighten pipe to manifold bolt/nuts to 34 Nm (25 ft. lbs.).
8. Install the torque converter to drive plate bolts and tighten to 31 Nm (23 ft. lbs.).
9. Install the inspection cover.
10. Install the starter motor.
11. Install a new engine oil filter.
12. Install the engine to transmission struts.
13. Insert transmission oil cooler lines into the transmission connectors until an audible "click" is heard. Verify connection by pulling apart connection.
14. Install cooler lines to retaining clips mounted at oil pan fasteners.
15. Lower vehicle.
16. Install the intake manifold.
17. Install the throttle body assembly with a new gasket and tighten bolts to 23 Nm (200 in. lbs.).
18. Install the A/C compressor (if equipped).
19. Install the generator assembly.
20. Install the power steering pump.
21. Install the accessory drive belt.
22. Connect all electrical and vacuum connections.
23. Lay the cooling fan shroud on top of the viscous fan.
24. Install the radiator.
25. Install the upper radiator support.
26. Attach the radiator upper and lower hoses to the radiator.
27. Fasten the cooling fan shroud to the radiator.
28. Install the transmission oil cooler.
29. Remove the protective caps and install the A/C condenser (if equipped).
30. Install the PDC, coolant recovery bottle and w/washer bottle to the radiator support.
31. Install the cowl plenum to radiator support rods.
32. Install the grille and mounting bracket.
33. Fill the crankcase with new engine oil.
34. Fill the cooling system.
35. Start engine and check for fluid and exhaust leaks.
36. Road test vehicle.