Removal Procedure

Engine Replacement

Tools Required

^ J 36857 Engine Lift Brackets
^ J 43181 Quick Connect Connector Removal

Removal Procedure

Important: In order to remove the engine the vehicle needs to be on a hoist. The front wheels and tires will also require removal. The vehicle will have to be supported by the frame when the tires are removed.





1. Recover the air conditioning (A/C) system. Refer to Refrigerant Recovery and Recharging.
2. Disconnect the negative battery cables.
3. Move the hood to the service position by moving the hood hinge bolts (1) to the service position (2).
4. Drain the cooling system. Refer to Draining and Filling Cooling System (Static Fill) Draining and Filling Cooling System (w/RPO HP2) Draining and Filling Cooling System (Vac-N-Fill).





5. Disconnect the following engine wire harness connectors:
^ Mass air flow switch (1)
^ A/C pressure cycling switch (2)
^ Surge tank switch (6)
6. Remove the engine wire harness clip from the accumulator (3).
7. Remove the engine wire harness clips from the wheelhouse inner panel (4).
8. Remove the engine wire harness clip from the engine bracket (5).
9. Remove the air cleaner.
10. Remove the surge tank.
11. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.
12. Remove both front tires and wheels.
13. Remove both fender wheelhouse inner panels.
14. Lower the vehicle.
15. Remove the charged air cooler pipes.





16. Loosen the hose clamps and remove the radiator inlet hose from the radiator and the engine.
17. Remove the upper fan shroud.
18. Remove the lower fan shroud.





19. Loosen the hose clamp and remove the radiator outlet hose from the radiator.
20. Disconnect the outlet heater hose from the outlet radiator hose.
21. Remove the hose clips from the frame.





22. Loosen the hose clamp and remove the radiator outlet hose from the engine.
23. Remove the outlet heater hose pipe bolt from the bracket.
24. Remove the outlet heater hose pipe nut (1).
25. Move the heater hose and secure aside.
26. Remove the upper radiator support.
27. Remove the radiator.
28. Remove the charged air cooler.
29. Remove the A/C condenser.





30. Disconnect the following electrical connectors:
^ Generator connector (1)
^ A/C refrigerant switch (2)
^ Dual generator harness connector (3), if equipped
^ A/C compressor clutch (4)
31. Remove the harness clip from the A/C compressor bracket.





32. Remove the battery cable to the generator.
33. If equipped, remove the battery cable to the auxiliary generator.
34. Remove the battery cable harness clip from the bracket.
35. Remove the battery cable junction block bolt (1) from the power steering pump.
36. Move and secure the battery cables out of the way.





37. Disconnect the main engine electrical harness connectors. Lift up on the latches (1) in order to disconnect the connectors.
38. Open the harness clip (2).
39. Remove the main engine electrical harness connectors.





40. Disconnect the fuel lines at the engine.
41. Remove the nut and the fuel line bracket from the upper valve rocker arm cover stud.
42. Secure the fuel lines out of the way.





43. Remove the drive belt.
44. Disconnect the suction hose from the accumulator. The compressor end can remain on the compressor.
45. Remove the A/C compressor bolts.
46. Move the A/C compressor with the hoses attached to the right side of the engine compartment.
47. Move the wiring harness to the left side of the vehicle and secure out to the way.





48. Remove the bolts retaining the power steering pump front bracket to the power steering pump and the air conditioner compressor mounting bracket.
49. Remove the air conditioning and power steering pump mounting bracket.





50. Remove the right idler pulley bolt (1) and pulley.





51. Remove the generator mounting bracket and secure to the side.
^ The generator does not require removal.
^ The drive belt tensioner does not require removal.





52. Use the J 43181 in order to disconnect the inlet heater hose from the heater core inlet.
53. Remove the bolt and the ground wires at the rear of the left cylinder head.
54. Raise the vehicle.





55. Remove the oil pan skid plate.





56. Remove the engine shield from the vehicle, if equipped.





57. Remove the bolt for the battery negative cable and the engine wiring harness ground wire from the left side of the engine.





58. Remove the bolts holding the battery cable channel retainer to the lower crankcase.





59. Disconnect the cord for the engine coolant heater.
60. Remove the starter.





61. Remove the nut holding the battery cable bracket to the right side of the lower crankcase.





62. Remove the bolt holding the auxiliary battery negative cable and the engine wiring harness ground wires to the right side of the engine.
63. Move and secure the battery cables out of the way.





64. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
65. Drain the engine oil.
66. Remove the exhaust pipe to the exhaust outlet clamp. Move the clamp onto the exhaust pipe.
67. If vehicle is 4-wheel drive (4WD) remove the lower oil pan. Refer to Lower Oil Pan Replacement.





68. If equipped with an automatic transmission, mark the flywheel and torque converter relationship for assembly purposes.
69. Remove the torque convertor bolts through the starter opening.





70. If equipped with an automatic transmission, remove the transmission oil line clip nut.





71. If equipped with an automatic transmission, remove the nuts retaining transmission fluid fill tube bracket.





72. Remove the transmission to engine stud and bolts (automatic transmission shown). Note the location of the studs and any brackets attached to the studs.





73. Lower the vehicle to work through the wheelhouse opening.
74. Remove the engine mount to frame bracket bolts (left side shown).
75. Lower the vehicle.





76. Install the J 36857 (1) to the rear of the left cylinder head with a suitable bolt.





77. Install the J 36857 (1) to the front of the right cylinder head with a suitable bolt.
78. Install a suitable lifting device. The engine will have to be angled in order to remove. Use a load positioning sling to assist in angling the engine.





79. Raise the vehicle off of the engine mounts.
80. Remove the left and right engine mount frame brackets.
81. Remove the engine from the vehicle.
82. In order to secure the engine to an engine stand remove the following and follow the special procedures:
^ Refer to Engine Flywheel Removal (Automatic Transmission) Engine Flywheel Removal (Manual Transmission).
^ Refer to Exhaust Outlet Removal.
^ Refer to Upper Oil Pan Removal.
^ Refer to Engine Flywheel Housing Removal.
^ Refer to Engine Mounting to Stand.