Removal
Engine ReplacementRemoval Procedure
Notice: If the engine is damaged internally and a new engine assembly is installed in the vehicle, ensure that all foreign material is flushed out of the cooling system. You must also flush out the oil cooler system. Failure to rid the oil cooler system of debris can result in engine damage.
Tool Required
- J 41427 Engine Lift Bracket
1. Disconnect the battery negative cable.
2. Raise the vehicle.
3. Remove the underbody shields.
4. Remove the braces from the engine to the transmission (manual transmission only).
5. Remove the exhaust pipe from the exhaust manifolds.
6. Disconnect the oil cooler pipes (RWD vehicle).
7. Disconnect the remote oil filter adapter inlet and outlet hoses (Four Wheel Drive vehicle).
8. Remove the bolt holding the starter wire harness and if equipped, transmission cooler lines.
9. Remove the starter.
10. Remove the transmission cover.
11. Disconnect the torque convertor bolts from the flywheel, if equipped with automatic transmission.
12. Disconnect the front propeller shaft (Four Wheel Drive only).
13. Remove the transfer case, if equipped.
14. Remove the rear engine mount to crossmember nut.
15. Remove the crossmember.
16. In order to remove the top transmission bolts lower the rear of the transmission after removing the crossmember.
17. Remove the transmission.
18. Remove the front engine mount through bolts.
19. Lower the vehicle.
20. Remove the PCV tube from the right valve rocker arm cover and the air cleaner outlet duct.
21. Remove the air cleaner outlet duct from the throttle body.
22. Remove the air cleaner assembly.
23. Remove the radiator.
24. Remove the inlet and outlet radiator hoses from the engine.
25. Disconnect the heater hoses from the engine.
26. Disconnect the following electrical connectors:
- The fuel meter body assembly
- The EVAP canister purge solenoid valve
- The idle air control (IAC) motor
- The throttle position (TP) sensor
- The A/C compressor high pressure switch, if equipped
- The A/C clutch switch, if equipped
- The exhaust gas recirculation (EGR) valve
- The engine coolant temperature (ECT) sensor
- The ignition control module (ICM)
- The generator
- The crankcase position (CKP) sensor
27. Release the engine wiring harness retainers and move the wiring harness aside.
28. Remove the battery ground cable at the engine.
29. Remove the bolts holding the ground wires to the left cylinder head.
30. Remove the bolt holding the fuel pipe bracket to the rear of left cylinder head.
31. Remove the bolts holding the ground wires to the right cylinder head.
Caution: To help avoid potential personal injury or potential damage to the vehicle due to possible cable damage during service, replace the existing accelerator control cable with a NEW cable when removing or replacing the engine. Position the cruise control cable out of the way to ensure it is not damaged while removing or installing the engine. Do not bend the cruise control cable and cause a kink at the bend. Do not position the cruise control cable where the technician may lean or pry against the cable and cause damage to the cable.
32. Remove the accelerator control cable from the throttle shaft and the accelerator cable bracket.
33. Remove the cruise control cable, if equipped from the throttle shaft and the accelerator cable bracket.
34. Remove the accelerator control cable bracket from the throttle body.
35. Remove the water pump pulley.
36. Remove the A/C compressor, if equipped.
37. Remove the nut holding the AIR reactor pipe bracket to the front of the engine, if equipped.
38. Remove the nuts holding the power steering pump rear bracket to the engine.
39. Remove the power steering pump mounting bracket.
- The power steering pump can remain on the mounting bracket.
- The hoses do not require removal.
- Remove the three bolts and the nut.
- Slide the mounting bracket off of the stud.
- Secure the mounting bracket out of the way.
40. Remove both of the secondary air injection (AIR) reactor pipes from the engine.
41. Remove the AIR shut-off valve and hoses.
42. Remove the distributor cap.
43. Disconnect the fuel pipes at the rear of the intake manifold.
44. Disconnect the EVAP canister purge solenoid valve pipe.
45. Disconnect the vacuum brake booster line from the intake manifold.
46. Remove the water outlet.
47. Remove the EGR valve inlet pipe from the intake and the exhaust manifolds.
48. Attach the J 41427 to the left front and the right rear intake manifold mounting bolts, using the following procedure:
1. Remove the right rear lower intake manifold bolts.
2. Install the J 41427 marked RIGHT REAR.
3. Install the retaining bolts.
4. Remove the left front lower intake manifold bolts.
5. Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of the engine.
6. Install the retaining bolts.
Tighten the retaining bolts to 15 N.m (11 lb ft).
49. Attach a suitable lifting device to the engine lift brackets.
50. Remove the engine.