Engine Removal

- Tools Required
- J41427Engine Lift Bracket
- J 41602 Body Protection Hoist Adapter Set
- J 39580 Universal Engine Support Table





Important: This procedure must be performed on a side lift hoist. The engine and front frame assembly will be removed out of the bottom of the vehicle, therefore, a single post hoist or a twin post hoist cannot be used to perform this procedure.

Notice: Failure to flush out the oil cooling system or the Cooling System system may result in premature failure of the replacement engine.

If the engine is damaged internally and a new engine is installed, make sure that all foreign material is completely flushed out of the cooling system.
The oil cooler system should be also be flushed out, if equipped.
1. Disconnect the battery negative cable.
2. Remove the engine cover.
3. Remove the air cleaner assembly.
4. Remove the air cleaner outlet duct from the throttle body.
5. Remove the radiator.
6. Disconnect the air conditioning pipes at the accumulator and the condenser, if equipped.
- Refer to Compressor/Condenser Hose Replacement-Auxiliary (YF7) in Heating and Air Conditioning Systems.
- Refer to Compressor/Condenser Hose Replacement-Auxiliary (Coo) in Heating and Air Conditioning Systems.
- Refer to Compressor/Condenser Hose Replacement-Auxiliary (Cog) in Heating and Air Conditioning Systems.

Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.

In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.
7. Remove the accelerator control cable from the throttle shaft.
8. Remove the cruise control cable, if equipped from the throttle shaft.
9. Remove the accelerator control cable and the cruise control cable from the accelerator control cable bracket.
10. Remove the power steering reservoir and drain the fluid.





11. Disconnect the pipes from the hydra boost unit. Refer to Hydraulic Brake Booster Replacement in Brakes and Traction Control.
12. Disconnect the master cylinder from the hydra boost unit.
13. Tie the master cylinder to the oil fill tube.
14. Disconnect the steering shaft from the steering gear.
15. Disconnect the heater hoses from the engine.
16. Disconnect the vacuum hose from the water control valve.
17. Disconnect the wire connector from the water control valve.
18. Disconnect the fuse box and the wiring harness from the bulkhead connector. Refer to Bulkhead/Underhood Fuse-Relay Center Wiring (Electrical) in Diagnostic Aids.
19. Disconnect all related electrical connectors that connect the wiring harness to the body under the hood including the following:
- The ground wires
- The accumulator
- The cruise control module
- The wiper motor
20. Remove the wiring harness from the retainers and lay the harness on the engine.





21. Remove the front section of the running boards, if equipped.
22. Install the J41602to the pinch weld area on both sides of the vehicle.
23. Position the front hoist arms under the J 41602.
24. Make sure the rear of the vehicle is slightly higher than the front.
25. Raise the vehicle.





26. Remove the oil pan drain plug and drain the engine oil into a suitable container.
27. Remove the rear propeller shaft. Refer to Propeller Shaft Replacement-Rear in Transmission and Drivetrain.





28. Remove the starter.
29. Remove the transmission cover.
30. Remove the torque converter bolts through the starter opening.
31. Disconnect the shift cable from the transmission.
32. Disconnect the wire connector from the wiring harness above the transmission.
33. Disconnect the exhaust system at the main flange behind the catalytic converter.
- Refer to Catalytic Converter Replacement (Rear Wheel Drive) in Engine Exhaust.
- Refer to Catalytic Converter Replacement (Automatic Four Wheel Drive) in Engine Exhaust.





34. Remove the park brake bracket from the frame.
35. Disconnect the rear brake pipe from the brake pressure modulator valve (BPMV). Refer to Brake Pressure Modulator Valve Replacement in Brakes and Traction Control.
36. Remove the front bumper.
37. Disconnect the power steering cooler from the front air deflector.
38. Disconnect the inflatable restraint front end discriminating sensor electrical connector.
39. Disconnect the fender wheelhouse extensions from the chassis to the frame.
40. Disconnect the rear air conditioning pipes at the rear crossmember, if equipped.
Leave the air conditioning pipes attached to the powertrain assembly.
- Refer to Accumulator Tube Replacement-Auxiliary Side in Heating and Air Conditioning Systems.
- Refer to Evaporator Tube Replacement-Auxiliary Side in Heating and Air Conditioning Systems.
41. Disconnect the fuel pipes at the fuel filter.
42. Pull the fuel pipes through the crossmember (forward). Lay the fuel pipes on the transmission.
43. Disconnect the fuel tank electrical connector.
44. Disconnect the EVAP vent valve electrical connector.
45. Remove the bolt and the ground wire at the chassis by the EVAP vent valve.
46. Make sure all the connections are disconnected between the chassis and the frame.
47. Disconnect the transfer case vent hose, if equipped.





48. Position the J 39580 under the frame assembly.
49. Lower the vehicle.
50. Adjust J 39580 to properly support the frame assembly with the engine, transmission, front suspension components, and front differential carrier assembly, if equipped.





51. Remove the body mount bolts (1), (2) and (3).
52. Place a jack stand under the transmission crossmember to prevent the frame assembly from tipping off of the J 39580.
53. Raise the hoist in order to separate the body from the frame assembly.
54. Install support stands under the rear axle.





55. Remove the EGR valve inlet pipe from the intake manifold and the exhaust manifold.
56. Disconnect the spark plug wires from the spark plugs.
Remove the distributor cap with the spark plug wire harness.
58. Remove the air conditioning compressor and the power steering pump mounting bracket.





59. Install the J 41427 using the following procedure:
59.1. Remove the two right rear lower intake manifold bolts.
59.2. Install the J41427 marked RIGHT REAR.

Notice: Refer to Fastener Notice in Service Precautions.

59.3. Install the retaining bolts.
Tighten the retaining bolts to 15 Nm (11 inch lbs.).
59.4. Remove the two left front lower intake manifold bolts.
59.5. Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of the engine.
59.6. Install the retaining bolts
Tighten the retaining bolts to 15 Nm (11 ft. lbs.).





60. Remove the engine mount through bolts.





61. Remove the bolt holding the fuel pipe bracket to the rear of the left cylinder head.
62. Disconnect the fuel pipes at the rear of the engine.
63. Disconnect the electrical harness at the transmission.
64. Disconnect all the wire harness connections and the ground wires from the engine and move the harness aside.
- Refer to Engine Wiring, RH Side in Diagnostic Aids.
- Refer to Engine Wiring, LH Side (Components) in Diagnostic Aids.
65. Remove the transfer case to engine block brace, if equipped.
66. Raise the engine slightly. Support the front of the transmission with suitable floor stand and a block of wood. Do not support the transmission under the oil pan.
67. Remove the exhaust pipe from the exhaust manifolds.
- Refer to Catalytic Converter Replacement (Rear Wheel Drive) in Engine Exhaust.
- Refer to Catalytic Converter Replacement (Automatic Four Wheel Drive) in Engine Exhaust.





68. Remove the transmission to engine bolts.
69. Disconnect the engine from the transmission.
70. Remove the engine from the frame.