Engine - Removal

REMOVAL

Special Tools:






CAUTION:
If the original engine has experienced a catastrophic failure or an individual failure with the piston, cylinder bore, engine block, valve or valve seat, the intake manifold MUST be replaced with a new manifold.





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

1. Release fuel rail pressure Service and Repair then disconnect the fuel supply quick connect fitting at the fuel rail Service and Repair.

2. Disconnect the battery negative and positive cables.

3. Raise vehicle on hoist.

4. Remove exhaust crossover pipe (5) from exhaust manifolds.

5. 4X4 vehicles Disconnect axle vent tube from left side engine mount.





6. Remove the through bolt retaining nut and bolt from both the left and right side engine mounts.

7. 4X4 vehicles Remove locknut from left and right side engine mount brackets.

8. Disconnect two ground straps from the lower left hand side and one ground strap from the lower right hand side of the engine.

9. Disconnect crankshaft position sensor (1).

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

10. 4X4 vehicles Remove the axle isolator bracket from the engine, transmission and the axle.





11. Remove structural cover Structural Dust Cover - Removal.





12. Remove starter (4) Service and Repair.

13. Drain cooling system Service and Repair.

14. Remove torque converter bolts (Automatic Transmission Only).

15. Remove transmission to engine mounting bolts.

16. Disconnect the engine block heater power cable from the block heater, if equipped.

17. Lower vehicle.

18. Remove throttle body resonator assembly and air inlet hose.

19. Disconnect throttle and speed control cables.





20. Disconnect tube from both the left and right side crankcase breathers (1). Remove breathers.





21. Discharge A/C system Service and Repair.

22. Remove A/C compressor (2) Service and Repair.

23. Remove shroud, fan assembly and accessory drive belt.

24. Disconnect transmission oil cooler lines at the radiator.

25. Disconnect radiator upper and lower hoses.

26. Remove radiator Engine Cooling Radiator - Removal , A/C condenser A/C Condenser - Removal and transmission oil cooler.





27. Remove generator (3) Service and Repair.





28. Disconnect the two heater hoses from the timing chain cover and heater core.

29. Unclip (2) and remove heater hoses (1) and tubes from the intake manifold.

30. Remove power steering pump and position out of the way.

31. Remove intake manifold.





32. Install Engine Lifting Fixture (10101).





33. Disconnect body ground strap (1) at the right side cowl.





34. Disconnect ground strap (1) at the left side cowl.

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

35. Position a suitable jack under the transmission.

36. Remove engine from the vehicle.