Steps 1-45

Engine Replacement

- Tools Required
- J 41427 Engine Lift Bracket

Removal Procedure





1. Disconnect the battery negative cable.
2. Drain the engine coolant.
3. Evacuate and recover the A/C refrigerant, if equipped.
4. Raise the vehicle. Refer to Vehicle Lifting.
5. Remove the oil pan skid plate (RWD shown).
6. Remove the engine shield, if equipped.
7. Remove the starter.





8. Remove the transmission cover.





9. Remove the bolt holding the bracket for the starter cables and transmission cooler lines, if equipped.





10. Loosen the nuts (2) at the catalytic converter pipe.
11. Remove the exhaust pipes from the exhaust manifolds.





12. Remove the bolts holding the brackets to the oil pan for both battery cables.





13. Disconnect the Crankshaft Position (CKP) sensor electrical connector (2) and remove the harness from the retainer.
14. Disconnect the low oil level sensor electrical connector (3) and remove the wire harness from the retainer.
15. Remove the bolt holding the battery negative cable (1) and a ground cable (1) to the engine.





16. Remove the torque converter to flywheel bolts, if equipped, through the starter opening.
17. Remove the engine to transmission bolts.
18. Lower the vehicle.





19. Move the hood hinge bolts (1) to hold the hood in the service position (2).





20. Separate the MAF/IAT sensor assembly and the air inlet tube by loosening the hose clamp.
21. Disconnect the PCV hose from the air cleaner outlet duct.





22. Remove the air inlet tube and resonator retaining wing nut.





23. Remove the air inlet tube and resonator from the throttle body by pivoting the air inlet tube and resonator upward until the hinge clip releases from the lip on the throttle body.
24. Remove the upper and lower fan shrouds.
25. Remove the drive belt.
26. Remove the engine cooling fan.
27. Remove the radiator inlet hose from the engine.
28. Remove the radiator outlet hose from the engine.





Caution: In order to avoid possible Injury or vehicle damage, always replace the accelerator control cable. 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 loan against the cruise control cable and do not kink the cable. You must replace a damaged cable.

29. Remove the accelerator cable from the cable routing bracket.





30. Remove the accelerator cable from the throttle body lever.
31. Disconnect the cruise control cable, if equipped from the throttle shaft and the accelerator cable bracket at the side of the throttle body.





32. Remove the engine wiring harness clip from the accelerator control cable bracket.
33. Remove the accelerator control cable bracket with the accelerator control cable and the cruise control cable from the throttle body.
34. Move and secure the accelerator control cable and the cruise control cable out of the way.
35. Disconnect the A/C hoses from the compressor and the accumulator, if equipped.





36. Remove the secondary air injection (AIR) crossover pipe from the AIR pipe assemblies.





Notice: Remove the AIR pipes before engine removal. The AIR pipes can break or damage easily causing erratic engine operation.

37. Remove AIR pipe assemblies from the left exhaust manifold, if equipped.





38. Disconnect the AIR pipe assembly from the AIR pump.
39. Remove the AIR pipe assembly from the right exhaust manifold, if equipped.





40. Disconnect the following electrical connectors:
- The A/C pressure switch (4), if equipped
- The A/C compressor clutch (1), if equipped
- The Exhaust Gas Recirculation (EGR) valve (2)
- The generator battery positive cable (3)





41. Disconnect the following electrical connectors:
- The fuel meter body assembly (3)
- The Idle Air Control (IAC) motor (2)
- The Throttle Position (TP) sensor (1)
- The Engine Coolant Temperature (ECT) sensor(4)





42. Disconnect the following electrical connectors:
- The EVAP canister purge solenoid valve (1)
- The Manifold Absolute Pressure (MAP) sensor(2)
- The Ignition Control Module (ICM) (4)
- The ignition coil (3)





43. Disconnect the following electrical connectors:
- The engine oil pressure gauge sensor (3)
- The distributor (2)
- The knock sensor (KS) (1)





44. Remove the nuts holding the bracket for the engine wiring harness to the intake manifold studs.
45. Remove the bolt holding the engine wiring harness clip to the battery positive cable junction block bracket.