B. Engine Replacement (WD/WK Models)

1. Move the passenger seat fully forward, disconnect and isolate the negative battery cable at the battery located under the passenger seat.

2. Mark the hood hinge location on the hood. Then remove and save the hood.

3. Remove and save the plastic engine cover.

4. Remove and save the air inlet resonator and the air cleaner body.





5. Remove and save the electric vacuum pump and mounting bracket (Figure 2).

6. Raise the vehicle on an appropriate hoist.

7. If equipped, remove and save the front skid plate, front suspension skid plate, transmission skid plate and the transfer case skid plate.

8. Drain and discard the engine cooling system coolant.

9. Drain and discard the engine oil.

10. Remove and save the nut and bolt from the support brackets of the heater core return tube.

11. Remove and save the A/C compressor mounting studs.

12. Lower the vehicle.

13. Remove and save the push clip from the support bracket of the heater core return tube and reposition the tube.

14. Disconnect the vapor purge tube from the fuel purge solenoid.

15. Remove and save the upper windshield cowl assembly.

16. Remove and save the windshield wiper arms and wiper linkage.

17. Remove and save the lower windshield cowl assembly.

18. Remove and save the HVAC air inlet duct.

19. Remove and save the upper intake manifold and foam insulator.

20. Disengage the clips, remove the make-up air tube from the left cylinder head cover and reposition the transmission vent hose.

21. Disconnect the fuel supply hose from the underbody fuel tube.

22. Remove and save the cooling fan module.





23. Remove and save the accessory drive belt (Figure 3).

24. Remove and save the generator.

25. Disconnect the right and left upstream oxygen sensor connectors from the main wire harness.

26. Remove and save the upper air conditioning compressor fasteners and relocate the compressor. Use bungee cords to hold compressor.

27. Loosen the lower catalytic converter flange bolts.

28. Remove the upper catalytic converter flange bolts and reposition the right and left catalytic converters.

29. Remove the bolts and the engine mount heat shield from both the left and right engine mounts.





30. Disconnect the electrical connectors from the variable valve timing solenoids on the left cylinder head (Figure 4).

31. Disengage the starter harness to main harness retaining clip.

32. Disengage the two starter wire harness retainers from the right cylinder head cover.

33. Disconnect the electrical connector from the right Camshaft Position sensor.

34. Disengage the main wire harness retainer from the right cylinder head cover mounting stud.

35. Disengage the four main wire harness retainers from the right cylinder head cover.

36. Disconnect the oil pump solenoid electrical connector.

37. Disengage the four wire harness retainers.

38. Remove the ground strap from the right engine mount bracket.

39. Disconnect the electrical connectors from the right variable valve timing solenoids.

40. Disengage the two starter wire harness retainers from the left cylinder head cover.

41. Disconnect the A/C compressor electrical connector and disengage the wire harness retainer from the A/C compressor discharge line.

42. Disengage the starter wire harness retainers from the upper intake manifold support brackets.

43. Disengage one main wire harness retainer from the left cylinder head cover and two retainers from the upper intake manifold support brackets.

44. Disconnect the Engine Coolant Temperature (ECT) sensor connector.

45. Disconnect the left camshaft position sensor.

46. Disengage one main wire harness retainer from the cylinder head cover and one main wire harness retainer from the cylinder head cover mounting stud.

47. Disengage the main wire harness retainer from the rear of the lower intake manifold.

48. Remove the upper radiator hose from the engine thermostat housing.

49. Raise and support the vehicle.

50. Remove the lower radiator hose from the engine coolant pump housing.

51. Disconnect the heater core return hose.





52. If equipped with AWD, remove and save the front differential assembly (Figure 5).





53. Remove and save the starter motor (Figure 6).

54. Disengage the starter wire harness retainer and the main wire harness retainer from the engine block.

55. Remove and save the starter wiring heat shield.

56. If the engine is seized, continue to Step 60.

57. Rotate the crankshaft in a clockwise direction until the torque converter bolts are accessible through the starter hole. Remove the six torque converter bolts.

58. Reinstall the left engine mount bracket and isolator assembly with the mounting bolts.

59. Unclip the transmission cooler line retainer from the upper oil pan flange.

60. Push back the heat shield from the crankshaft position sensor.

61. Disconnect the main wire harness from the crankshaft position sensor.

62. Disengage one main wire harness retainer from the engine block and one main wire harness retainer from the right engine mounting bracket.

63. If equipped with a block heater, disconnect and reposition the power cord from the engine block heater.

64. Remove and save the bolt securing the transmission fluid level indicator tube to the transmission housing.

65. Remove and save the transmission fluid level indicator tube.

66. Remove the four upper transmission-to-engine mounting bolts.

67. Remove the torque converter dust shield and mounting bolt.

68. Remove the side engine-to-transmission mounting bolt.

69. Remove the two rubber plugs covering the rear oil seal retainer flange bolts.

70. Remove the four lower transmission-to-engine oil pan bolts.

71. Lower the vehicle.

72. Remove the engine oil level indicator tube.

73. Remove the heater core supply tube and mounting bolt.

74. Disconnect the heater core supply tube at the front of the engine.

75. Disconnect the main harness from the engine injection/ignition harness at the rear of the left cylinder head.

76. Disconnect the main harness from the engine oil pressure/temperature harness at the rear of the left cylinder head.

77. If equipped with AWD, disengage the transfer case vent hose retainer from the upper intake manifold support bracket.

78. Remove the left upper intake manifold support brackets and mounting bolts.

79. Install the Driver Side Engine Lifting Bracket 10242-1 on the left cylinder head with bolts provided with the Engine Lifting Bracket. Tighten the bolts to 15 ft. lbs. (21 N.m).

80. Install the Passenger Side Engine Lifting Bracket 10242-2 on the right cylinder head with bolts provided with the Engine Lifting Bracket. Tighten the bolts to 15 ft. lbs. (21 N.m).

81. Reposition the starter wire harness and the main wire harness to the rear of the engine compartment.

82. Position a load-leveling lifting sling, such as OTC(R) 4305 Engine Load Leveler or equivalent, between the engine lifting brackets and an engine hoist.

83. Support the transmission with a suitable jack.

84. Remove both the left and right engine mount bracket bolts (two per side).

85. Carefully remove the engine from the engine bay area.

CAUTION:
While slowly separating the engine from the vehicle, constant checks must be made to assure proper positioning and that no damage to other components or wiring harnesses occurs during the separation process.

86. Transfer all components from the original engine to the replacement engine.





87. For seized engines, remove the torque converter bolts and remove the torque converter from the flex plate (Figure 7).

88. For seized engines, install the original torque converter into the transmission.

89. Remove the intake manifold from the replacement engine.

90. Remove the lifting brackets (Special Tool 10242-1 and 10242-2) from the original engine and install the right and left lifting brackets on the cylinder heads of the replacement engine. Tighten the lift bracket bolts to 15 ft. lbs. (21 N.m).

91. Position a load-leveling lifting sling, such as OTC(R) 4305 Engine Load Leveler or

92. Reposition the starter wire harness and the main wire harness to the rear of the engine compartment.





CAUTION:
Make sure to align the flex plate holes with the torque converter lugs before installing the engine. The torque converter lugs will not clear the welds for the ring gear (Figure 8).

95. Position the engine in the vehicle while aligning the two locator dowels into the transmission housing.

96. Install the four upper transmission-to-engine bolts. Tighten the bolts to 41 ft. lbs. (55 N.m).

97. Align the tab on the isolators with the notch in the engine mount brackets and lower the engine so the weight is resting on the isolators.

98. Install the left and right engine mount bolts and tighten to 45 ft. lbs. (61 N.m).

99. Remove the engine lifting brackets and install the left upper intake manifold support brackets. Loosely install the stud-bolts.

100. Route the main wire harness and starter wire harness on the engine.

101. Engage two starter wire harness retainers to the upper intake manifold support brackets.

102. Engage one main wire harness retainer to the left cylinder head cover and two retainers to the upper intake manifold support brackets.

103. Connect the Engine Coolant Temperature (ECT) sensor connector.

104. Connect the electrical connector to the left Camshaft Position (CMP) sensor.

105. Engage one main wire harness retainer to the cylinder head cover and one main wire harness retainer to the cylinder head cover mounting stud.

106. Engage the main wire harness retainer to the rear of the lower intake manifold.

107. Connect the electrical connector to the right Camshaft Position (CMP) sensor.

108. Engage the main wire harness retainer to the right cylinder head cover mounting stud.

109. Engage the four main wire harness retainers to the right cylinder head cover.

110. Connect the electrical connectors to the variable valve timing solenoids on the right cylinder head.

111. Engage the two starter wire harness retainers to the right cylinder head cover.

112. Engage the starter harness to main harness retainer.

113. Connect the oil pump solenoid electrical connector.

114. Engage the four wire harness retainers.

115. Install the ground strap to the right engine mount bracket.

116. Raise and support the vehicle.

117. Install the four transmission-to-engine oil pan bolts. Tighten the bolts to 41 ft.lbs. (55 N.m).

118. Install the two rubber plugs covering the rear oil seal retainer flange bolts.

119. Install the side engine-to-transmission bolt. Tighten the mounting bolt to 41 ft. lbs. (55 N�m).

120. Install the torque converter dust shield with the mounting bolt. Tighten the mounting bolt to 106 in. lbs. (12 N.m).

121. Install the transmission fluid indicator tube.

122. Install the bolt securing the transmission fluid level indicator tube to the transmission housing and tighten to 106 in. lbs. (12 N.m).

123. Connect the main harness to the engine oil pressure/temperature harness at the rear of the left cylinder head.

124. For vehicles with AWD, raise the rear of the engine, reinstall six crossmember bolts and three crossmember brace bolts. Tighten all bolts to 41 ft. lbs. (55 N.m).

125. Rotate the crankshaft in a clockwise direction and install the six torque converter bolts through the starter hole. Tighten the bolts to 31 ft. lbs. (42 N.m).

126. Clip the transmission cooler line retainer to the oil pan flange.

127. Engage the starter wire harness retainer and the main wire harness retainer to the engine block.

128. Install the starter.

129. If equipped with a block heater, connect the power cord to the engine block heater.

130. Connect the main wire harness to the crankshaft position sensor.

131. Engage one main wire harness retainer to the engine block and one main wire harness retainer to the right engine mounting stud.

132. Position the heat shield over the crankshaft position sensor.

133. If equipped with AWD, install the front differential assembly.

134. Lower the vehicle.

135. If equipped with AWD, engage the transfer case vent hose retainer to the upper intake manifold support bracket.

136. Install the heater core supply tube with one bolt and tighten to 106 in. lbs. (12 N.m).

137. Install the engine oil level indicator tube with bolt tightened 106 in. lbs. (12 N.m).

138. Install the A/C compressor with two bolts tightened to 18 ft.lbs. (25 N.m).

139. Connect the heater core return hose.

140. Install the lower radiator hose to the engine coolant pump housing.

141. Install the upper radiator hose to the engine thermostat housing.

142. Connect the main harness to the engine injection/ignition harness at the rear of the left cylinder head.

143. Connect the electrical connectors to the left variable valve timing solenoids.

144. Engage the two starter wire harness retainers to the left cylinder head cover.

145. Connect the A/C compressor electrical connector and engage the wire harness retainer to the A/C compressor discharge line.

146. Install the engine mount heat shield to both the left and right engine mounts with two bolts tightened to 106 in. lbs. (12 N.m).

147. Install the right and left catalytic converters onto the partially installed lower catalytic converter flange bolts.

148. Install the upper catalytic converter flange bolts and tighten bolts to 17 ft. lbs. (23 N.m).

149. Connect the right and left upstream oxygen sensor connectors to the main wire harness.

150. Install the generator.

151. Install the accessory drive belt.

152. Install the cooling fan module.

153. Connect the fuel supply hose to the underbody fuel tube.

154. Install the upper intake manifold and insulator.

155. Install the make-up air tube to the left cylinder head cover and engage the clips to the transmission vent hose.

156. Install the PCV hose to the PCV valve.

157. Install the vapor purge tube to the fuel purge solenoid.

158. Install the nut to the support bracket of the heater core return tube and tighten to 106 in. lbs. (12 N.m).

159. Raise and support the vehicle.

160. Install the A/C compressor mounting studs and tighten to 18 ft. lbs. (25 N.m).

161. Install the nut and bolt to the support brackets of the heater core return tube. Tighten to 106 in. lbs. (12 N.m).

162. If equipped, install the transfer case skid plate, the transmission skid plate, the front suspension skid plate and the front skid plate.

163. Lower the vehicle.

164. Install the HVAC air inlet duct.

165. Install the lower windshield cowl assembly.

166. Install the windshield wiper arms and wiper linkage.

167. Install the upper windshield cowl assembly.

168. Install the electric vacuum pump and mounting bracket.

169. Install the air inlet resonator and the air cleaner body.

170. Fill the cooling system with coolant.

171. Check the engine oil level and fill as required.

172. Install the plastic engine cover.

173. Tighten the fuel fill cap.

174. Install and align the hood.

175. Install the fuel pump fuse into the Power Distribution Center (PDC).

176. Connect the negative battery cable and tighten nut to 45 in. lbs. (5 N.m).

177. Run the engine until it reaches normal operating temperature. Check cooling system and transmission for correct fluid level.

178. Turn off the engine and recheck the engine oil level. Add oil as required.