Removal and Replacement

Engine Replacement

Tools Required
- J 44220 Engine Lift Bracket


Removal Procedure

1. Remove the hood.
2. Disconnect the negative battery cable.
3. Drain engine coolant.
4. Recover the refrigerant.

Important: Keep drain plug removed during engine removal and installation.







5. Remove the oil pan drain plug and drain the oil.
6. Install a suitable plug into the oil pan after draining to prevent any oil leakage during the rest of the procedure.
7. Remove the air cleaner assembly.
8. Remove the throttle body.
9. Remove the map sensor.
10. Remove the washer solvent container.
11. Remove the air intake baffle.
12. Remove the grill.
13. Remove the headlamp housing.
14. Remove the radiator support brace.
15. Remove the hood latch.
16. Disconnect A/C lines at the condenser.
17. Disconnect the transmission cooler lines at the engine, not the radiator.
18. Remove the cooling fan and the shroud tilting the radiator forward, and the cooling fan and the shroud rearward for clearance.
19. Remove the radiator with condenser and transmission cooler lines.
20. Remove the drive belt.
21. Remove the power steering pump bolts and lay the pump aside.







22. Ensure the heater hoses at the heater core are disconnected.







23. Disconnect the transmission filler tube bracket nut from the AIR adapter.







24. Remove the AIR adapter.







25. Install the lift hook J 44220 to the AIR adapter.
26. Disconnect the oxygen sensor electrical connector.
27. Disconnect the A/C line at the accumulator.
28. Disconnect the front axle actuator electrical connector.
29. Disconnect the camshaft phaser actuator valve electrical connector.







30. Unclip the transmission cooler lines from right side of the engine block.
31. Disconnect the ignition coil harness connectors.







32. Carefully disconnect harness retainer at clips (1) and remove.
33. Remove power brake hose at booster.







34. Remove the PCM.







35. Disconnect the full lines at the fuel pressure regulator and cap lines.
36. Remove all harnesses from the engine harness bracket.







37. Disconnect the front differential vent hose from the engine harness bracket.
38. Remove the engine harness bracket bolt and remove bracket.
39. Disconnect starter electrical connections (1).
40. Disconnect the A/C pressure sensor and clutch electrical connector.







41. Disconnect generator electrical connector and battery lead.
42. Disconnect the knock sensor electrical connector.
43. Disconnect the crankshaft sensor electrical connector.
44. Disconnect the camshaft sensor electrical connector.







45. Remove 4 grounds on the left side of the block (1).
46. Raise the vehicle. Refer to Vehicle Lifting.
47. Remove the wheel drive shafts, left and right.
48. Remove the propeller shaft from the front axle pinion yoke.
49. Remove the engine protection shield.







50. Disconnect the exhaust pipe from the exhaust manifold and slide the exhaust pipe backward slightly.
51. Remove the fuel tank shield, if equipped.
52. Remove the torque converter bolt access cover.
53. Remove the torque converter bolts.
54. Place a jack on the transmission oil pan for support.
55. Remove the transmission support.
56. Lower the transmission enough to reach the top bell housing bolts.
57. Remove the top 4 bell housing bolts, there may be 2 harness clips that will need to be removed in order to have access to 2 of the top bolts.
58. Raise the transmission.
59. Reinstall the transmission support using only 2 through bolts.
60. Remove the remaining bell housing bolts, for a total of 11 bolts.
61. Remove the left and right engine lower mount nuts.
62. Disconnect the oil lever sensor electrical connector.
63. Disconnect the oil pressure switch electrical connector.
64. Lower the vehicle.







65. Remove the left upper engine mount nut.







66. Remove the right upper engine mount nut.
67. Install the engine hoist.
68. Raise the engine out of the compartment slowly keeping the transmission supported.
69. Remove both engine mount for clearance.
70. Continue raising the engine out of the vehicle.
71. Install the engine to the engine stand.




Installation Procedure







1. Remove the engine from the engine stand.
2. Slowly install the engine into the engine compartment aligning the engine mounts with the brackets.
3. When the engine mounts are aligned, install the engine mounts, putting the mount up through the engine mount brackets before inserting into the chassis mount brackets.



NOTICE: Refer to Fastener Notice in Service Precautions.
Fastener Notice


4. Lower the engine onto the mounts and install the upper engine mount nuts.
^ Tighten the nuts to 70 Nm (51 ft. lbs.).
5. Remove the engine hoist.
6. Lay the radiator into the radiator support, but do not install the radiator completely.
7. Raise the vehicle. Refer to Vehicle Lifting.
8. Install all of the lower bell housing bolts, excluding the top four.
9. Remove the two through bolts securing the transmission support.
10. Lower the transmission.
11. Install the top four bell housing bolts.
Tighten all eleven bell housing bolts to 50 Nm (37 ft. lbs.).

12. Raise the transmission.
13. Install the transmission support.
14. Install the 3 torque converter bolts.
Tighten the torque converter bolts to 60 Nm (44 ft. lbs.).

15. Install the torque converter bolt cover.
16. Install the fuel tank shield, if removed.
17. Install the engine protection shield.
18. Install the propeller shaft to the front axle pinion yoke.
19. Connect the exhaust pipe to the manifold and secure the pipe with the bolts.
Tighten the exhaust pipe bolts to 50 Nm (37 ft. lbs.).

20. Connect the oil level switch electrical connector.
21. Connect the oil pressure sensor electrical connector.







22. Install the oil pan drain plug.
Tighten the plug to 26 Nm (19 ft. lbs.).







23. Install the lower radiator hose (1).
24. Install the left and right wheel drive shafts.
25. Lower the vehicle.







26. Install the 4 grounds on the left side of the block (1).
27. Install the camshaft sensor electrical connectors.
28. Install the crankshaft sensor electrical connector.
29. Install the knock sensor electrical connector.







30. Install the generator electrical connector and battery lead (1).
Tighten the generator battery lead nut to 9 Nm (80 inch lbs.).

31. Install the A/C pressure sensor and clutch electrical connector.





32. Install starter electrical connectors and battery lead (1).
Tighten the starter battery lead to 9 Nm (80 inch lbs.).

33. Install the fuel lines at the fuel pressure regulator.







34. Install the engine harness bracket and bolt.
Tighten the engine harness bracket bolt to 50 Nm (37 ft. lbs.).

35. Install the front differential vent hose, to the engine harness bracket.
36. Install all the harnesses to the engine harness bracket.
37. Install the PCM.
38. Install the power brake hose at booster





39. Install the harness retainer to the original location.
40. Install the ignition coil harness electrical connectors.







41. Clip the transmission cooler lines to the right side of the engine block.
42. Connect the camshaft phaser actuator valve electrical connector.
43. Connect the front axle actuator electrical connector.
44. Connect the A/C line at the accumulator.
45. Install the oxygen sensor electrical connector.





46. Remove the lift hook J 44220.





47. Install the AIR adapter and secure the adapter with the studs.
Tighten the AIR adapter studs to 25 Nm (18 ft. lbs.).







48. Install the transmission filler tube bracket to AIR adapter stud and secure the bracket with the nut.
Torque nut to 10 Nm (89 inch lbs.).

49. Install the heater hoses to the heater core.
50. Install the power steering pump.







51. Install the power steering pump bolts.
Tighten the bolts to 25 Nm (18 ft. lbs.).

52. Install the drive belt.
53. Install cooling fan and shroud, tilting the radiator forward for clearance.
54. Finish installing the radiator.
55. Install transmission cooler lines together.
56. Install map Sensor.
57. Install the throttle body.
58. Install the hood latch.
59. Install the head lamp housing.
60. Install the grill.
61. Install the air intake baffle.
62. Install the washer solvent container.
63. Install the air cleaner assembly.
64. Connect the negative battery cable.
65. Install the hood.
66. Service the engine oil.
67. Fill the cooling system.
68. Recharge the refrigerant.
69. Perform the CKP system variation learn procedure.

Important: After an overhaul, the engine should be tested. Use the following procedure after the engine is installed in the vehicle.
- Disable the ignition system.
- Crank the engine several times. Listen for unusual noises or evidence that parts are binding.
- Enable the ignition system.
- Start the engine and listen for unusual noises.
- Check the vehicle oil pressure gage or light and confirm that the engine has acceptable oil pressure.
- Run the engine speed at about 1000 RPM until the engine has reached normal operating temperature.
- Listen for a sticking lifter and other unusual noises.
- Inspect for fuel, oil and/or coolant leaks while the engine is running.
- Perform a final inspection for the proper engine oil and coolant levels.

70. Install the hood.