Removal and Replacement
Removal ProcedureCaution: Refer to Battery Disconnect Caution in Service Precautions.
1. Disconnect the battery negative cable.
2. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
3. Evacuate and recover the air conditioning (A/C) refrigerant, if equipped. Refer to Refrigerant Recovery and Recharging in Heating and Air Conditioning.
4. Raise the hood to the servicing position. Move the hood hinge bolt (1) to hold the hood in the servicing position (2).
5. Remove the upper and the lower radiator hoses from the engine. Refer to Radiator Hose Replacement in Cooling System.
6. Remove the air cleaner duct from the engine. Refer to Air Cleaner Assembly Replacement in Powertrain Management.
7. Remove the A/C condenser mounting bolts, if equipped. Refer to Condenser Replacement in Heating and Air Conditioning.
8. Remove the radiator support from the vehicle. Refer to
8.1. For the upper radiator support, refer to Radiator Support Replacement (Base) or Radiator Support Replacement (Upper).
8.2. For the general radiator support, refer to Radiator Support Replacement (Base) or Radiator Support Replacement (Upper).
9. Remove A/C compressor. Refer to Compressor Replacement (LR4, LM7, La4 w/ Denso) or Compressor Replacement (L35 w/ Harrison) in Heating and Air Conditioning.
10. Remove the coolant hose from the throttle body.
11. Remove both of the heater hoses from the engine and the cowl. Refer to Heater Hoses Replacement in Heating and Air Conditioning.
12. Remove the engine sight shield from the intake manifold. Refer to Engine Sight Shield Replacement.
13. Remove the accelerator control cable mounting bracket from the intake manifold.
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.
14. Remove the accelerator control cable and the cruise control cable, if equipped, from the throttle shaft. Refer to Accelerator Controls Cable Replacement in Powertrain Management.
15. Open the large electrical harness retainer. Remove one 10 mm nut in order to release the engine harness from the intake manifold.
16. Disconnect the following electrical connectors:
^ The eight injector connectors
^ The idle air control (IAC) motor
^ The throttle position (TP) sensor
^ The evaporative emissions (EVAP) canister purge solenoid
^ The manifold absolute pressure (MAP) sensor
^ The camshaft position (CMP) sensor
^ The ground splice at the rear of the right side of the block
^ The ground splice and the ground strap at the rear of the left side of the block
^ The coolant temperature (CTS) sensor
^ The oil pressure sensor/switch
^ the electrical connector from intake and disconnect from harness
^ junction block bracket from generator bracket
17. Set the electrical harness aside.
18. Disconnect the EVAP canister purge solenoid vent tube from the solenoid by squeezing the retainer, then release the tube from the solenoid. Refer to Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement in Powertrain Management.
19. Remove the battery negative cable from the engine block.
20. Remove the drive belt. Refer to Drive Belt Replacement (Accessory) or Drive Belt Replacement (A/C).
21. Remove the generator. Refer to Generator Replacement.
22. Remove the generator mounting bracket from the engine using the following steps:
^ Remove the bolts holding the generator mounting bracket to the cylinder head and block.
^ Remove the bolt behind the power steering pump to engine block.
^ Remove the generator mounting bracket.
23. Position the bracket aside.
24. Disconnect the fuel pipes from the engine. Refer to Quick Connect Fitting(s) Service (Metal Collar) in Powertrain Management.
25. Raise the vehicle. Refer to Vehicle Lifting.
26. Remove the steering linkage under body shield, if equipped.
27. Remove the engine oil pan under body shield, if equipped.
28. Drain the engine oil. Refer to Engine Oil and Oil Filter Change.
29. Remove the starter motor. Refer to Starter Motor Replacement.
30. Disconnect the engine wiring harness from the following components:
^ The crankshaft position (CKP) sensor
^ The engine oil level sensor
^ The block heater, if equipped
^ The wiring harness to oil pan
^ Remove the wiring from lower engine area
31. Remove the exhaust pipes from the exhaust manifolds. Refer to the appropriate procedure in Exhaust Systems from the following list:
^ Catalytic Converter Replacement.
^ Front Pipe Replacement
^ Spark Plug Replacement
32. Remove the transmission cooler pipe retainer from the right side of the engine block, if equipped.
33. Remove the torque converter shield from the engine.
34. Remove the torque converter bolts.
35. Remove the nut and the transmission oil level
indicator tube from the bellhousing stud.
36. Remove the lower bellhousing studs from the engine. Refer to the appropriate procedure from the following list:
^ Transmission Replacement in Manual Transmission-NV 3500
^ Transmission Replacement in Manual Transmission-NV 4500
^ Transmission Replacement in Automatic Transmission-4L60-E
^ Transmission Replacement in Automatic Transmission-4L80-E
37. Lower the vehicle.
38. Remove remaining bellhousing bolts.
39. Position the engine electrical harness aside.
40. Remove ignition coil(s) (as required) for the proper fit of the J41798 before lifting the engine. Refer to Ignition Coil(s) Replacement (Ignition Coils and Bracket).
Notice: Refer to Fastener Notice in Service Precautions.
41. Install the J41798 engine lift brackets to the cylinder heads.
^ Tighten the engine lift bracket bolts (M10) to 50 Nm (37 ft. lbs.).
^ Tighten the engine lift bracket bolts (M8) to 25 Nm (18 ft. lbs.).
42. Install a lifting device onto the J41798engine lift brackets.
43. Install floor jack or stands to transmission for support.
44. Remove the engine mount bolts. Refer to Engine Mount Replacement.
Notice: Use care while moving the engine assembly in order to avoid breaking the MAP sensor locating tabs. Broken MAP sensor tabs may result in decreased engine performance.
45. Remove the engine from the vehicle.
Installation Procedure
Notice: Use care while moving the engine assembly in order to avoid breaking the MAP sensor locating tabs. Broken MAP sensor tabs may result in decreased engine performance.
1. Install the engine to the vehicle.
2. Install the engine mount bolts. Refer to Engine Mount Replacement.
3. Install upper bellhousing bolts.
4. Remove transmission support apparatus.
5. Remove the lifting device from the J41798 lift brackets.
6. Remove the J41798 lift brackets from both cylinder heads.
7. Install the ignition coil(s) and the spark plug wire(s). Refer to Ignition Coil(s) Replacement (Ignition Coils and Bracket).
8. Route the engine wiring harness to the lower right hand side of the engine.
9. Raise the vehicle. Refer to Vehicle Lifting.
10. Install remaining bellhousing bolts.
11. Install torque converter bolts.
12. Install torque converter shield
13. Install transmission oil level indicator tube and nut to bellhousing stud.
14. Install the A/C compressor. Refer to Compressor Replacement in Heating and Air Conditioning.
15. Install transmission cooler pipe retainer to right side of engine block.
Refer to the appropriate procedure from the following list:
^ Transmission Replacement in Manual Transmission-NV 3500
^ Transmission Replacement in Manual Transmission-NV 4500
^ Transmission Replacement in Automatic Transmission-4L60-E
^ Transmission Replacement in Automatic Transmission-4L80-E
^ Install the engine exhaust pipes to the exhaust manifolds. Refer to the appropriate procedure.in Exhaust Systems from the following list:
^ Catalytic Converter Replacement.
^ Front Pipe Replacement
16. Reroute wiring to lower engine area and install bolt to oil pan.
17. Connect electrical connectors to the following:
^ crankshaft position (CKP) sensor
^ engine oil level sensor
^ block heater, if equipped
18. Install the starter motor. Refer to Starter Motor Replacement.
19. Install the engine oil pan under body shield, if equipped.
20. Install the steering linkage under body shield.
21. Lower the vehicle.
22. Connect the fuel pipes to the engine. Refer to Quick Connect Fitting(s) Service (Metal Collar) in Powertrain Management.
Notice: Refer to Fastener Notice in Service Precautions.
23. Install the generator mounting bracket to the cylinder head using the nuts and the bolts.
Tighten the bolts to 50 Nm (37 ft. lbs.).
24. Install the bolt at the rear of the power steering pump to the engine block.
Tighten the bolt to 50 Nm (37 ft. lbs.).
25. Install the generator to the engine. Refer to Generator Replacement.
26. Install the drive belt. Refer to Drive Belt Replacement (Accessory) or Drive Belt Replacement (A/C)
27. Install the battery negative cable to the engine block. Refer to Fastener Tightening Specifications.
28. Install the EVAP canister purge solenoid to the intake manifold. Refer to Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement in Powertrain Management.
29. Route the engine harness over the top of the engine. Connect the following components:
^ The eight injector connectors
^ The idle air control (IAC) motor
^ The throttle position (TP) sensor
^ The EVAP canister purge solenoid.
^ The manifold absolute pressure (MAP) sensor
^ The camshaft position (CMP) sensor
^ The ground splice at the rear of the right side of engine block
^ The ground splice and the ground strap at the rear of the left side of engine block
^ The Coolant Temperature (CTS) sensor
^ The oil pressure sensor/switch
30. Install the nut to the engine wiring harness bracket.
Tighten the nut to 10 Nm (89 inch lbs.).
Caution: in order to avoid possible injury or vehicle damage, a/ways 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.
31. Install a NEW accelerator control cable. Refer to Accelerator Controls Cable Replacement in Powertrain Management. Install cruise control cable, if equipped, to the throttle shaft. Refer to Accelerator Controls Cable Replacement in Powertrain Management.
32. Install the bolts for the accelerator control cable mounting bracket.
Tighten the bolts to 10 Nm (89 inch lbs.).
33. Install the engine sight shield to the intake manifold. Refer to Engine Sight Shield Replacement.
34. Install both heater hoses to the cowl and the engine. Refer to Heater Hoses Replacement in Heating and Air Conditioning with A/C-Manual.
35. Install the coolant hose to the throttle body.
36. Install the radiator support in the vehicle. Refer to
36.1. For the upper radiator support, refer to Radiator Support Replacement (Base) or Radiator Support Replacement (Upper).
36.2. For the general radiator support, refer to Radiator Support Replacement (Base) or Radiator Support Replacement (Upper).
37. Install the A/C condenser mounting bolts, if equipped. Refer to Condenser Replacement in Heating and Air Conditioning.
38. Install the air cleaner duct. Refer to Air Cleaner Assembly Replacement in Powertrain Management
39. Install the upper and the lower radiator hoses to the engine. Refer to Radiator Hose Replacement in Cooling System.
40. Lower the hood. Refer to Hood Replacement.
41. Fill the engine with oil. Refer to Engine Oil and Oil Filter Change.
42. Fill the engine with coolant. Refer to Draining and Filling Cooling System in Cooling System.
43. Connect the negative battery cable.