Engine Replacement

REMOVAL PROCEDURE

^ Tools Required
- J 36857 Engine Lift Bracket





1. Drain the cooling system.
2. Evacuate the Air conditioning system.
3. Remove the front battery from the vehicle.
4. Disconnect the battery cables from the auxiliary battery.
5. Remove the engine cover from the vehicle.
6. Remove the air intake duct from the vehicle.
7. Remove the air cleaner from the vehicle.
8. Remove the surge tank from the vehicle.
9. Remove the front bumper from the vehicle.
10. Remove the grille assembly from the vehicle.
11. Remove the auxiliary engine oil cooler from the vehicle.
12. Remove the A/C condenser from the vehicle.
13. Remove the radiator from the vehicle.
14. Remove the radiator support from the vehicle.
15. Remove the drive belt from the vehicle.
16. Remove the fan clutch from the water pump.
17. Remove the radiator hoses from the engine assembly.
18. Remove the engine oil fill tube. Refer to Oil Fill Tube Removal under Engine Unit Repair.
19. Remove the engine oil level indicator and tube from the engine assembly.
20. Remove the upper intake manifold from the engine block.
21. Remove the engine wiring harness from the engine.
22. Remove the lower intake manifold from the engine assembly.
23. Remove the transmission oil level indicator from the engine assembly.
24. Remove the ground wires from the engine assembly.
25. Remove the turbocharger from the engine block.
26. Remove the thermostat housing crossover from the engine assembly.
27. Remove the heater hoses from the vehicle.
28. Remove the A/C compressor from the mounting bracket.
29. Remove the auxiliary generator (if equipped from the mounting bracket.
30. Remove the power steering pump from the mounting bracket.
31. Remove the mounting bracket from the engine block.
32. Remove the generator from the mounting bracket.
33. Remove the vacuum lines to vacuum pump.
34. Remove the mounting bracket from the engine block.
35. Remove the exhaust manifolds (if needed).
36. Remove the fuel injection pump from the engine block.
37. Raise the vehicle and support with safety stands.





38. Disconnect the block heater electrical connector.
39. Remove the starter from the engine block.
40. Remove the engine oil cooler lines from the engine block.
41. Remove the transmission cooler lines from the retaining clips.
42. Remove the flywheel inspection cover.
43. Remove the bolts from the flywheel to the torque convertor.
44. Remove the lower bolts from the transmission the engine block.
45. Remove the nuts from the engine mount through bolts.
46. Remove the safety stands and lower the vehicle.
47. Support the transmission with a suitable support.
48. Remove the upper bolts from the transmission to the engine.





49. Install the J 36857 on the right rear cylinder head.
50. Install the J 36857 on the left front cylinder head.
51. Install a suitable lifting device between the lifting brackets.
52. Lift the engine just enough to remove the engine mount through bolts.
53. Remove the engine assembly from the vehicle.
54. Install the engine assembly on a suitable engine stand.

IMPORTANT: It maybe necessary to remove the flywheel from the crankshaft before installing the engine assembly on a suitable engine stand.

55. Remove the lift brackets from the engine assembly.

INSTALLATION PROCEDURE





1. Install the J 36857 to the right rear cylinder head.
2. Remove the engine from the engine stand.
3. Install the flywheel on the crankshaft.
4. Lower the engine assembly on the engine mounts.
5. Install the engine mount through bolts.
6. Install the right and left lower bolt from the transmission to the engine block.
7. Remove the lifting device from the engine assembly.
8. Raise the vehicle and support with safety stands.
9. Install the upper bolts from the transmission to the engine block.
10. Install the bolts from the flywheel to the torque convertor.
11. install the nuts to the engine mount through bolts.
12. Install the starter to the engine block.
13. Install the flywheel inspection cover to the transmission.
14. Install the engine oil cooler lines to the engine block.
15. Install the transmission oil cooler lines to the retaining clips.





16. Reconnect the block heater electrical connector.
17. Remove the safety stands and lower the vehicle.
18. Install the fuel injection pump to the engine block.
19. Install the exhaust manifolds (if removed).
20. Install the mounting bracket for the A/C compressor.
21. Install the mounting bracket for the generator.
22. Install the vacuum lines to the vacuum pump.
23. Install the generator to the mounting bracket.
24. Install the power steering pump to the mounting bracket.
25. Install the auxiliary generator (if equipped) to the mounting bracket.
26. Install the turbocharger to the engine block.
27. Install the lower intake manifold to the engine block.
28. Install the ground wires from the body to the engine block.
29. Install the thermostat housing crossover to the engine assembly.
30. Install the heater hoses to the vehicle.
31. Install the A/C compressor to the engine block.
32. Install the engine wiring harness to the engine assembly.
33. Install the upper intake manifold to the engine assembly.
34. Install the transmission oil level indicator to the vehicle.
35. Install the engine oil level indicator to the engine assembly.
36. Install the engine oil filler tube. Refer to Oil Fill Tube Removal under Engine Unit Repair.
37. Install the radiator hoses to the engine assembly.
38. Install the A/C compressor to the mounting bracket.
39. Install the clutch fan to the water pump.
40. Install the drive belt on the pulleys.
41. Install the radiator support in the vehicle.
42. Install the radiator in the vehicle.
43. Install the A/C condenser in the vehicle.
44. Install the auxiliary engine oil cooler.
45. Install the grille assembly to the vehicle.
46. Install the front bumper to the vehicle.
47. Install the surge tank in the vehicle.
48. Install the air cleaner in the vehicle.





49. Install the air intake duct to the air cleaner.
50. Connect the battery cables to the auxiliary battery.
^ For the positive battery cable.
^ For the negative battery cable.

51. Install the front battery in the vehicle.
52. Fill the cooling system.
53. Recharge the A/C system.
54. Perform the injection timing adjustment procedure.
55. Perform the TDC offset timing procedure.
56. Install the engine cover in the vehicle.