Engine - Removal

REMOVAL

Special Tools:










1. Disconnect the battery negative cable.
2. Remove air cleaner assembly.
3. Remove radiator core support bracket.
4. Remove fan shroud with viscous fan assembly.
5. Remove drive belt.
6. Remove A/C compressor (Figure 1) (2) and secure away from engine.





7. Remove generator (Figure 2) (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 (Figure 3) :
- 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. Release fuel rail pressure.
20. 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.

21. Remove the PCV hose.
22. Remove the breather hoses.
23. Remove the vacuum hose for the power brake booster.
24. Disconnect knock sensors.
25. Remove engine oil dipstick tube.
26. Remove intake manifold(Figure 4).

27. Install engine lifting fixture, special tool # , 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.

28. Secure the left and right engine wiring harnesses away from engine.
29. Raise vehicle.
30. Disconnect oxygen sensor wiring.
31. Disconnect crankshaft position sensor.
32. Disconnect the engine block heater power cable, if equipped.




33. Disconnect the front propshaft at the front differential and secure out of way.

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

34. Remove the starter (Figure 5) (4).









35. Remove the ground straps from the left (Figure 7) (2) and right (Figure 6) (3) side of the block.
36. Disconnect the right and left exhaust pipes at the manifolds and from the crossover, and remove from the vehicle.

NOTE: The exhaust clamps at the manifolds cannot be reused. New clamps must be used or leaks may occur.






37. Remove the structural cover(Figure 8).
38. Remove torque converter bolts, and mark location for reassembly.
39. Remove transmission bellhousing to engine bolts.
40. Remove left and right engine mount thru bolts.
41. Lower the vehicle.
42. Support the transmission with a suitable jack.
43. Connect a suitable engine hoist to the engine lift plate.
44. Remove engine from vehicle.