Removal and Replacement

ENGINE

REMOVAL

NOTE: This procedure applies to both the 4X2 and 4X4 vehicles, steps that apply to the 4X4 vehicle only, are identified.

1. Discharge A/C system.
2. Drain cooling system.
3. Release fuel rail pressure
4. Remove air cleaner assembly.
5. Disconnect battery.
6. Remove upper fan shroud.
7. Remove accessory drive belt .
8. Remove viscous fan.
9. Remove A/C compressor and position out of the way.
10. Remove generator and secure away from engine.

NOTE: Do NOT remove the phenolic pulley from the P/S pump. It is not required for P/S pump removal.

11. Remove power steering pump with lines attached and secure away from engine.
12. Disconnect the heater hoses from the engine.
13. Disconnect heater hoses from heater core and remove hose assembly.
14. Remove upper radiator hose from engine.
15. Remove lower radiator hose from engine.
16. Disconnect transmission oil cooler lines at the radiator.
17. Remove radiator core support bracket.
18. Remove radiator assembly, A/C Condenser and transmission oil cooler.
19. Disconnect throttle and speed control cables.
20. Disconnect the engine to body ground straps at the left side of cowl.
21. Disconnect the engine wiring harness at the following points:
^ Intake Air Temperature (IAT) sensor
^ Fuel Injectors
^ Throttle Position (TPS) Switch
^ Idle Air Control (IAC) Motor
^ Engine Oil Pressure Switch
^ Engine Coolant Temperature (ECT) Sensor
^ Manifold Absolute Pressure (MAP) Sensor
^ Camshaft Position (CMP) Sensor
^ Coil Over Plugs
^ Crankshaft Position Sensor

22. Remove coil over plugs.
23. Remove fuel rail and secure away from engine.

NOTE: It is not necessary to release the quick connect fitting from the fuel supply line for engine removal.

24. Remove the PCV hose.
25. Remove the breather hoses.
26. Remove the vacuum hose for the power brake booster.
27. Disconnect knock sensors.
28. Remove engine oil dipstick tube.
29. Remove intake manifold.
30. Install engine lifting fixture,special tool 8247, using original fasteners from the removed intake manifold, and fuel rail. Torque to factory specifications.
31. Raise vehicle on hoist.
32. Remove exhaust crossover pipe from exhaust manifolds.
33. 4X4 vehicles Disconnect axle vent tube from left side engine mount.








34. Remove the through bolt retaining nut and bolt from both the left and right side engine mounts (Fig. 3) (Fig. 4).
35. 4X4 vehicles Remove locknut from left and right side engine mount brackets (Fig. 4).
36. Disconnect two ground straps from the lower left hand side and one ground strap from the lower right hand side of the engine.





37. Disconnect crankshaft position sensor. (Fig. 6)

NOTE: The following step applies to 4X4 vehicles equipped with automatic transmission only.





38. 4X4 vehicles Remove the axle isolator bracket from the engine, transmission and the axle (Fig. 5).
39. Remove structural cover.
40. Remove starter.
41. Remove torque converter bolts (Automatic Transmission Only).
42. Remove transmission to engine mounting bolts.
43. Disconnect the engine block heater power cable from the block heater, if equipped.
44. Lower vehicle.
45. Remove throttle body resonator assembly and air inlet hose.
46. Disconnect throttle and speed control cables.





47. Disconnect tube from both the left and right side crankcase breathers (Fig. 7). Remove breathers
48. Remove generator.
49. Disconnect the two heater hoses from the timing chain cover and heater core.





50. Unclip and remove heater hoses and tubes from the intake manifold (Fig. 8).
51. Disconnect engine harness at the following points:





^ Intake Air Temperature (IAT) sensor (Fig. 9)
^ Fuel Injectors
^ Throttle Position (TPS) Switch
^ Idle Air Control (IAC) Motor
^ Engine Oil Pressure Switch
^ Engine Coolant Temperature (ECT) Sensor
^ Manifold absolute pressure (MAP) Sensor
^ Camshaft Position (CMP) Sensor
^ Coil Over Pales

52. Disconnect the vacuum lines at the throttle body and intake manifold.
53. Remove power steering pump and position out of the way.





54. Disconnect body ground strap at the right side cowl (Fig. 10).





55. Disconnect body ground strap at the left side cowl (Fig. 11).

NOTE: It will be necessary to support the transmission in order to remove the engine.

56. Position a suitable jack under the transmission.
57. Remove engine from the vehicle.

INSTALLATION
1. Position engine in the vehicle.
Position both the left and right side engine mount brackets and install the through bolts and nuts. Tighten nuts to 4X2 vehicles 95 Nm (70 ft. lbs.). 4X4 vehicles 102 Nm (75 ft. lbs.).
2. 4X4 vehicles. Install locknuts onto the engine mount brackets. Tighten locknuts to 41 Nm (30 ft. lbs.).
3. Remove jack from under the transmission.
4. Remove Engine Lifting Fixture Special Tool 8347.
5. Remove Special Tools 8400 Lifting Studs.
6. Position generator wiring behind the oil dipstick tube, then install the oil dipstick tube upper mounting bolt.
7. Connect both left and right side body ground straps.
8. Install power steering pump.
9. Connect fuel supply line quick connect fitting.
10. Connect the vacuum lines at the throttle body and intake manifold.
11. Connect engine harness at the following points:
^ Intake Air Temperature (IAT) Sensor
^ Idle Air Control (IAC) Motor
^ Fuel Injectors
^ Throttle Position (TPS) Switch
^ Engine Oil Pressure Switch
^ Engine Coolant Temperature (ECT) Sensor
^ Manifold Absolute Pressure (MAP) Sensor
^ Camshaft Position (CMP) Sensor
^ Coil Over Plugs

12. Position and install heater hoses and tubes onto intake manifold.
13. Install the heater hoses onto the heater core and the engine front cover.
14. Install generator.
15. Install A/C condenser, radiator, and transmission oil cooler.
16. Connect radiator upper and lower hoses.
17. Connect the transmission oil cooler lines to the radiator.
18. Install accessory drive belt, fan assembly and shroud.
19. Install A/C compressor.
20. Install both breathers. Connect tube to both crankcase breathers (Fig. 7).
21. Connect throttle and speed control cables.
22. Install throttle body resonator assembly and air inlet hose. Tighten clamps 4 Nm (35 inch lbs.).
23. Raise vehicle.
24. Install transmission to engine mounting bolts. Tighten the bolts to 41 Nm (30 ft. lbs.).
25. Install torque converter bolts (Automatic Transmission Only).
26. Connect crankshaft position sensor (Fig. 6).
27. 4X4 vehicles. Position and install the axle isolator bracket onto the axle, transmission and engine block. Tighten bolts to specification.
28. Install starter.

CAUTION: The structural cover requires a specific torque sequence. Failure to follow this sequence may cause severe damage to the cover.

29. Install structural cover.
30. Install exhaust crossover pipe.
31. Install engine block heater power cable, If equipped.
32. 4X4 vehicles. Connect axle vent tube to left side engine mount.
33. Lower vehicle.
34. Check and fill engine oil.
35. Recharge the A/C system.
36. Refill the engine cooling system.
37. Install the battery tray and battery.
38. Connect the battery positive and negative cables.
39. Start the engine and check for leaks.