Removal and Replacement

REMOVAL - ENGINE





1. Release fuel rail pressure then disconnect the fuel supply quick connect fitting at the fuel rail.
2. Disconnect the battery negative cable.
3. Remove air cleaner assembly.
4. Remove fan shroud with viscous fan assembly.
5. Remove drive belt.
6. Remove A/C compressor (2) and secure away from engine.





7. Remove generator (3) 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.

8. Remove power steering pump with lines attached and secure away from engine.
9. Drain cooling system.
10. Disconnect the heater hoses from the engine.
11. Disconnect heater hoses from heater core and remove hose assembly.
12. Disconnect throttle and speed control cables.
13. Remove upper radiator hose from engine.
14. Remove lower radiator hose from engine.
15. Remove radiator/cooling module assembly.
16. Disconnect the engine to body ground straps at the left side of cowl.





17. Disconnect the engine wiring harness at the following points:
- Intake air temperature (IAT) sensor (4)
- Fuel Injectors
- Throttle Position (TPS) Switch (2)
- Idle Air Control (IAC) Motor (3)
- Engine Oil Pressure Switch
- Engine Coolant Temperature (ECT) Sensor
- Manifold Absolute Pressure MAP) Sensor
- Camshaft Position (CMP) Sensor
- Coil Over Plugs
- Crankshaft Position Sensor
18. Remove coil over plugs.





19. 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.

20. Remove the PCV hose.
21. Remove the breather hoses.
22. Remove the vacuum hose for the power brake booster.
23. Disconnect knock sensors.
24. Remove engine oil dipstick tube.
25. Remove intake manifold.
26. Install engine lifting fixture, special tool # 8247, using original fasteners from the removed intake manifold, and fuel rail. Torque to factory specifications.

NOTE: Recheck bolt torque for engine lift plate before removing engine.





27. Disconnect oxygen sensor wiring.
28. Disconnect crankshaft position sensor.
29. Disconnect the engine block heater power cable, if equipped.
30. Disconnect the front propshaft at the front differential and secure out of way.
31. Remove the pinion bracket.

NOTE: It is necessary to disconnect the front propshaft for access to the starter and left side exhaust flange.





32. Remove the starter (4).
33. Remove the ground straps from the right (1) side of the block.





34. Remove the ground straps from the left (1) side of the block.





35. Remove the structural cover.
36. Disconnect the right and left exhaust pipes at the manifolds and from the crossover, and remove from the vehicle.





37. Remove torque converter bolts (3), and mark location for reassembly.





38. Remove transmission bellhousing to engine bolts (3).
39. Remove left and right engine mount thru bolts (3).
40. Lower the vehicle.
41. Support the transmission with a suitable jack.
42. Connect a suitable engine hoist to the engine lift plate.
43. Remove engine from vehicle.

INSTALLATION - ENGINE





1. Position the engine in the vehicle.
2. Install the transmission bellhousing to engine mounting bolts (3). Tighten the bolts to 41 Nm (30 ft. lbs.)
3. Install the engine mount thru bolts.





4. Install the torque converter bolts (3).





5. Install the starter(4).
6. Connect the crankshaft position sensor.
7. Install the engine block heater power cable, if equipped.

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





8. Install the structural cover.
9. Install the pinion bracket.
10. Install the left and right exhaust pipes.
11. Connect the left and right oxygen sensors.
12. Remove the engine lift plate.
13. Connect the knock sensors.
14. Connect the engine to body ground straps at the left side of the cowl.





15. Install the intake manifold using the sequence provided.
16. Install the engine oil dipstick tube.
17. Install the power brake booster vacuum hose.
18. Install the breather hoses.
19. Install the PCV hose.
20. Install the fuel rail.
21. Install the coil over plugs.





22. Connect the engine wiring harness at the following points:
- Intake air temperature (IAT) sensor (4)
- Fuel Injectors
- Throttle Position (TPS) Switch (2)
- Idle Air Control (IAC) Motor (3)
- Engine Oil Pressure Switch
- Engine Coolant Temperature (ECT) Sensor
- Manifold Absolute Pressure MAP) Sensor
- Camshaft Position (CMP) Sensor
- Coil Over Plugs
- Crankshaft Position Sensor





23. Connect the ground straps on the right (3)side of the engine.





24. Connect the ground straps on the left (2) side of the engine.





25. Reinstall the radiator/cooling module assembly.
26. Connect lower radiator hose.
27. Connect upper radiator hose.
28. Connect throttle and speed control cables.
29. Install the heater hose assembly.
30. Install coolant recovery bottle.
31. Install the power steering pump.
32. Install the generator (3).





33. Install the A/C compressor (2).
34. Install the drive belt.
35. Install the fan shroud with the viscous fan assembly.
36. Install the radiator core support bracket.
37. Recharge the A/C system.
38. Install the air cleaner assembly.
39. Refill the engine cooling system.
40. Check and fill engine oil.
41. Connect the battery negative cable.
42. Start the engine and check for leaks.