Engine Replacement
Removal Procedure1. Disconnect the battery negative cable.
2. Remove the hood.
3. If the vehicle is equipped with a manual transmission, remove the shift lever.
4. Raise the vehicle.
5. Disconnect the exhaust pipe from the exhaust manifold.
6. Remove the oil filter drain deflector from the brace rod, if equipped.
7. Remove the starter motor.
8. In order to gain access to the top transmission bolts, lower the rear of the transmission after removing the crossmember. The engine and transmission will pivot on the engine mounts.
9. Remove the transmission.
10. Disconnect the oxygen sensor electrical connector.
11. Remove the right fender wheelhouse extension.
12. Working through the wheelhouse opening, remove the generator rear brace using the following procedure:
1. Remove the bolt from the rear of the generator.
2. Remove two nuts holding the brace to the engine.
3. Remove the brace from the engine.
13. Remove the bolt holding the battery negative cable (2) to the engine.
14. Remove the bolt holding the ground wires (1) to the engine.
15. Disconnect the following electrical connectors:
^ Engine oil pressure gauge sensor (6)
^ Camshaft Position (CMP) sensor (5)
^ Crankshaft Position (CKP) sensor (3)
^ Knock (KS) sensor (4)
16. Disconnect both Ignition Control Module (ICM) electrical connectors (2).
17. Disconnect the EVAP purge canister solenoid valve electrical connector.
18. Lower the vehicle.
19. Remove the bolt holding the EVAP emission canister purge harness and if equipped the automatic transmission fluid fill tube to the intake manifold.
20. Remove the nut holding the engine wiring harness clip to the intake manifold.
21. Remove the nut holding the engine wiring harness clip to the intake manifold rear lower stud.
22. Remove the air intake duct.
23. Remove the radiator.
24. Remove the drive belt.
Important: Do not evacuate the A/C system.
25. Remove the air conditioning compressor, if equipped, and set it aside.
26. Remove the power steering pump and set it aside.
27. Disconnect both heater hoses from the heater core.
28. Disconnect the heating and air conditioning control vacuum source hose.
29. Disconnect the EVAP emission purge tube from the throttle body.
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.
30. 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. Remove the accelerator control cable.
32. Disconnect the cruise control cable from the throttle shaft.
33. Disconnect the engine side of the battery positive cable from the mega fuse.
34. Disconnect the engine coolant heater, if equipped.
35. Disconnect the electrical connections from the generator.
36. Disconnect the following electrical connectors from the top of the engine:
^ Engine Coolant Temperature (ECT) sensor (3)
^ Idle Air Control (IAC) motor (1)
^ Manifold Absolute Pressure (MAP) sensor (4)
^ Throttle Position (TP) sensor (2)
37. Disconnect the fuel injector harness electrical connector.
38. Remove the fuel injector harness electrical connector from the bracket on the valve rocker arm cover.
39. Remove the engine wiring harness from the bracket.
40. Move and secure the engine wiring harness out of the way.
41. Disconnect the fuel hoses.
42. Disconnect the electrical connection from the generator.
43. Disconnect the generator output wire from the generator.
44. Move the engine wiring harnesses aside.
45. Install a suitable engine lifting device to the engine lift brackets.
46. Remove the left side engine mount through-bolt.
47. Remove the right side engine mount through-bolt.
48. Remove the engine from the vehicle.
Installation Procedure
1. Install the engine to the vehicle.
2. Install the right side engine mount through-bolt.
3. Install the left side engine mount through-bolt.
4. Remove the engine lifting device from the engine lift brackets.
5. Connect the fuel hoses.
6. Position the engine wiring harness.
7. Install the engine wiring harness to the bracket.
8. Install the fuel injector harness electrical connector to the bracket on the valve rocker arm cover.
9. Connect the fuel injector harness electrical connector.
10. Connect the following electrical connectors to the top of the engine:
^ Engine Coolant Temperature (ECT) sensor (3)
^ Idle Air Control (IAC) motor (1)
^ Manifold Absolute Pressure (MAP) sensor (4)
^ Throttle Position (TP) sensor (2)
11. Connect the engine coolant heater, if equipped.
12. Connect the generator electrical connectors.
13. Connect the engine side of the battery positive cable to the mega fuse.
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.
14. 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.
15. Install a NEW accelerator control cable.
16. Connect the cruise control cable to the throttle body, if equipped.
17. Install both heater hoses to the heater core.
18. Install the power steering pump.
19. Install the air conditioning compressor, if equipped.
20. Install the drive belt.
21. Install the radiator.
22. Install the air intake duct.
23. Connect the heating and air conditioning control vacuum source hose.
24. Connect the EVAP emission purge tube from the throttle body.
25. Install he bolt holding the EVAP emission canister purge harness and if equipped the transmission fluid fill tube.
Tighten the bolts to 10 Nm (89 inch lbs.).
26. Install the nut holding the engine wiring harness clip and the battery negative cable clip to the intake manifold.
Tighten the engine wiring harness clip nut to 10 Nm (89 ft. lbs.).
27. Install the nut holding the engine wiring harness clip to the intake manifold rear lower stud.
Tighten the engine wiring harness clip nut to 30 Nm (22 ft. lbs.).
28. Raise the vehicle to a height in order to work through the wheelhouse opening.
29. Connect the following electrical connectors to the right side of the engine:
^ Engine oil pressure sensor (6)
^ Camshaft Position (CMP) sensor (5)
^ Crankshaft Position (CKP) sensor (3)
^ Knock (KS) sensor (4)
30. Install the bolt and the ground wires (1) to the engine.
Tighten the ground wire bolt to 35 Nm (26 ft. lbs.).
31. Install the bolt and the battery negative cable (2) to the engine.
Tighten the battery negative cable bolt to 35 Nm (26 ft. lbs.).
32. Connect both Ignition Control Module (ICM) electrical connectors (2).
33. Connect the EVAP purge canister solenoid valve electrical connector (1).
34. Install the generator brace using the following procedure.
1. Install the brace to the engine.
2. Install the two nuts holding the brace to the engine.
3. Install the bolt to the rear of the generator.
Tighten the generator rear brace nuts and bolt to 25 Nm (18 ft. lbs.).
35. Install the right fender wheelhouse extension.
36. Connect the oxygen sensor electrical connector.
37. Install the transmission.
38. Install the starter motor.
39. Install the oil filter drain deflector on the transmission brace rod, if equipped.
40. Connect the exhaust pipe to the exhaust manifold.
41. Lower the vehicle.
42. Install the manual transmission shift lever, if removed.
43. install the hood.
44. Connect the battery negative cable.
45. Fill the crankcase with engine oil.
46. Fill the cooling system with coolant.
47. Recharge the A/C system, if equipped.
48. Operate and test the engine. Refer to Engine Set-Up and Testing. Engine Set-Up and Testing