Engine Removal and Installation
REMOVAL PROCEDURE- Tools Required
- J 41427 Universal Lift Brackets
CAUTION: Refer to Battery Disconnect Caution In Service Precautions.
1. Disconnect the battery negative cable.
2. Remove the hood.
3. Remove the air cleaner assembly.
4. Drain the engine coolant.
5. Remove the following coolant hoses:
- Remove the upper radiator hose.
- Remove the lower radiator hose.
- Remove both heater hoses.
6. Remove the upper and lower radiator shroud.
7. Remove the drive belt.
8. Disconnect the throttle cable and the cruise control cable, if equipped.
9. Remove the engine cooling fan.
10. Remove the air conditioning compressor, if equipped, and set it aside.
11. Disconnect the electrical connector from the power steering pump.
12. Remove the power steering pump pulley.
13. Remove the power steering pump mounting bracket using the following procedure:
- Disconnect the electrical connector from the power steering pump.
- Remove the nuts holding the power steering pump to the engine.
- Remove the power steering pump mounting bracket bolts and the nut.
- Slide the power steering pump mounting bracket forward with the power steering pump still attached.
- Remove the stud.
- Set the power steering pump and the mounting bracket aside.
14. Remove the starter motor.
15. Remove the starter opening cover.
16. Disconnect the electrical connectors on the top of the engine.
17. Disconnect the positive battery cable at the generator.
18. Remove the torque converter to flywheel bolts, if equipped.
19. Disconnect the transmission cooler pipe bracket from the right side of the oil pan, if equipped.
20. Remove the exhaust pipe from the exhaust manifolds.
21. Support the transmission with a suitable strap.
22. Remove the engine oil cooler pipes, if equipped.
23. Remove both engine mount through-bolts.
24. Remove seven transmission to engine bolts including the brackets.
25. Lower the vehicle.
26. Disconnect the remaining electrical connectors.
27. Remove the distributor cap.
28. Remove the engine harness support.
29. Disconnect the fuel pipes.
30. Remove two transmission to engine bolts at the top of the engine.
31. Remove the EGR pipe.
NOTICE: Refer to Fastener Notice in Service Precautions.
32. Attach the J 41427 to the left front and right rear intake manifold mounting bolts, using the following procedure:
- Remove the right rear lower intake manifold bolts.
- Install the J 41427 marked RIGHT REAR.
- Install the retaining bolts.
Tighten the bolts to 15 Nm (111 ft. lbs.).
- Remove the left front lower intake manifold bolts.
- Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of the engine.
- Install the retaining bolts.
Tighten the bolts to 15 Nm (11 ft. lbs.).
33. Attach a suitable lifting device to the lift brackets.
34. Remove the engine.
INSTALLATION PROCEDURE
- Tools Required
- J 41427 Universal Lift Brackets
1. Install the engine to the vehicle.
2. Install two top transmission to engine bolts, including the brackets and clips.
3. Remove the J 41427 and the lifting device.
NOTICE: Refer to Fastener Notice in Service Precautions.
4. Reinstall the intake manifold bolts.
Tighten the bolts to 15 Nm (11 ft. lbs.).
5. Install the EGR pipe.
6. Connect the fuel pipes.
7. Install the engine harness support.
8. Install the distributor cap.
9. Connect the engine harness.
10. Install the remaining seven transmission to engine bolts.
11. Install both engine mount through-bolts, if equipped.
12. Install the oil cooler pipes, if equipped.
13. Remove the transmission support strap.
14. Install the exhaust pipe to the exhaust manifolds.
15. Install the transmission cooler pipe bracket to the right side of the oil pan, if equipped.
16. Install three torque convertor to flywheel bolts, if equipped.
17. Install the starter opening shield.
18. Install the starter motor.
19. Connect the positive battery cable at the generator.
20. Connect the engine harness to the top of the engine.
21. Install the power steering pump mounting bracket using the following procedure:
- Loosely assemble the mounting bracket over the stud.
- Install a nut to the stud finger tight.
- Install the three bolts finger tight.
- Install the two nuts to the power steering pump finger tight.
Tighten the nuts and bolts to 41 Nm (30 ft. lbs.).
22. Install the air conditioning (A/C) compressor, if equipped.
23. Connect the electrical connector to the power steering pump.
24. Use the J 25033-B in order to install the power steering pump pulley.
25. Install the engine cooling fan.
26. Install the drive belt.
27. Connect the throttle cable and the cruise control cable, if equipped.
28. Install the air cleaner assembly.
29. Install the upper and lower radiator shrouds.
30. Install the following coolant hoses:
- The upper radiator hose.
- The lower radiator hose.
- Both heater hoses.
31. Fill the engine with coolant.
32. Install the hood.
33. Connect the battery negative cable.
34. Before starting a new engine, or one that has been repaired.
- Refer to Engine Set-Up and Testing under Engine Unit Repair.