Engine Replacement
Removal ProcedureNotice: 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
- J41427 Engine Lift Bracket
1. Disconnect the battery negative cable.
2. Remove the hood.
3. Raise the vehicle.
4. Remove the underbody shields, if equipped.
5. Remove the exhaust pipe from the exhaust manifolds.
6. Disconnect the engine oil cooler pipes (RWD vehicle).
7. Disconnect the remote oil filter adapter inlet and outlet hoses (4WD vehicle).
8. Remove the stud holding the starter wire harness and if equipped, transmission oil cooler lines.
9. Remove the starter.
10. Remove the transmission cover.
11. Remove the transmission.
12. Remove the front engine mount through bolts.
13. Lower the vehicle.
14. Remove the PCV tube from the right valve rocker arm cover and the air cleaner outlet duct.
15. Remove the air cleaner outlet duct 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.
16. 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.
17. Remove the accelerator control cable.
18. Remove the cruise control cable, if equipped from the throttle shaft and the accelerator cable bracket.
19. Remove the radiator.
20. Remove the inlet and outlet radiator hoses from the engine.
21. Disconnect the heater hoses from the engine.
22. Disconnect the power brake booster vacuum hose from the intake manifold.
23. Disconnect the vacuum hose for the A/C system, if equipped from the intake manifold.
24. Disconnect the following electrical connectors:
^ The A/C compressor clutch (1), if equipped
^ The A/C compressor cutoff switch (5), if equipped
^ The TP sensor (2)
^ The IAC valve motor (3)
^ The ECT sensor (4)
25. Disconnect the following electrical connectors:
^ The fuel meter body (1)
^ The EVAP canister purge solenoid (2)
^ The MAP sensor (3)
26. Disconnect the following electrical connectors:
^ The ICM (1)
^ The ignition coil (2)
^ The EGR solenoid (3)
^ The generator (4)
27. Disconnect the following electrical connectors:
^ The distributor (1)
^ The engine oil pressure sensor (2)
^ The KS sensor (3)
28. Disconnect the CKP sensor (2) electrical connector.
29. Remove the bolt and the battery negative cable (1).
30. Remove the engine wiring harness bracket bolt (3).
31. Remove the engine wiring harness clips from the front of the engine.
32. Remove the engine wiring harness clips from the brackets.
33. Move the engine wiring harness aside.
34. Remove the generator.
35. Remove the bolt holding the ground wires to the left cylinder head.
36. Remove the bolt holding the fuel pipe bracket to the rear of left cylinder head.
37. Remove the bolts holding the ground wires to the right cylinder head.
38. Remove the bolt holding the ground strap to the right cylinder head.
39. Remove the accelerator control cable bracket from the throttle body.
40. Remove the water pump pulley.
41. Remove the A/C compressor, if equipped.
42. Remove the nut holding the AIR reactor pipe bracket to the front of the engine, if equipped.
43. Remove the nuts holding the power steering pump rear bracket to the engine.
44. 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.
Notice: Remove the AIR pipes before engine removal. The AM pipes can break or damage easily causing erratic engine operation.
45. Remove both of the secondary Air Injection (AIR) reactor pipes from the engine.
46. Remove the AIR shut-off valve and hoses.
47. Remove the distributor cap
48. Disconnect the fuel pipes at the rear of the intake manifold.
49. Disconnect the EVAP canister purge solenoid valve pipe.
50. Remove the water outlet.
51. Remove the spark plug wire harness retainer from the Exhaust Gas Recirculation (EGR) valve inlet pipe.
52. Remove the clamp bolt for the EGR valve inlet pipe.
53. Remove the EGR valve inlet pipe from the intake and the exhaust manifolds.
54. Attach the J41427 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 J41427 marked RIGHT REAR.
3. Install the retaining bolts.
4. Remove the left front lower intake manifold bolts.
5. Install the J41427 marked LEFT FRONT with the arrow pointing to the front of the engine.
6. Install the retaining bolts.
Tighten the retaining bolts to 15 Nm (11 ft. lbs.).
55. Attach a suitable lifting device to the engine lift brackets.
56. Remove the engine.
Installation 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
- J41427 Engine Lift Bracket
1. Install the engine into the vehicle.
2. Install the engine mount through-bolts and nuts.
Tighten the engine mount through-bolts or the nuts to the following:
^ Tighten the through-bolts to 74 Nm (55 ft. lbs.)
^ Tighten the nuts to 63 Nm (46 ft. lbs.)
3. Remove the J41427 and the engine lifting device.
4. Apply threadlock to the threads of the lower intake manifold bolts.
5. Install the intake manifold bolts.
Tighten the bolts the first pass to 3 Nm (27 inch lbs.).
Tighten the bolts the first pass to 12 Nm (106 inch lbs.).
Tighten the bolts the first pass to 15 Nm (11 ft. lbs.).
6. Install the EGR valve inlet pipe to the intake manifold and the exhaust manifold.
Tighten the EGR valve inlet pipe intake manifold nut to 25 Nm (18 ft. lbs.).
Tighten the EGR valve inlet pipe exhaust manifold nut to 30 Nm (22 ft. lbs.).
Tighten the EGR valve inlet pipe clamp bolt 25 Nm (18 ft. lbs.).
7. Install the spark plug wire harness retainer on the EGR valve inlet pipe.
8. Install the water outlet.
9. Connect the fuel pipes at the rear of the engine.
10. Install the distributor cap.
11. Connect the EVAP canister purge solenoid valve pipe.
12. Install both of the AIR reactor pipes to the engine.
13. Install the AIR shut-off valve and hoses.
14. Install the power steering pump mounting bracket.
15. Install the nuts holding the power steering pump rear bracket to the engine.
Tighten the power steering pump rear bracket nuts to 41 Nm (30 ft. lbs.).
16. Install the nut holding the AIR reactor pipe bracket, if equipped to the stud on the front of the engine.
Tighten the bolt to 41 Nm (30 ft. lbs.).
17. Install the A/C compressor, if equipped.
18. Install the water pump pulley.
19. Install the accelerator control cable bracket to the throttle body.
Tighten the bolt to 9 Nm (80 inch lbs.).
20. Install the bolt holding the ground wires to the left cylinder head.
Tighten the ground wire bolt to 35 Nm (26 ft. lbs.).
21. Install the bolt holding the fuel pipe bracket to the rear of the left cylinder head Tighten the fuel pipe bracket bolt to 30 Nm (22 ft. lbs.).
22. Install the stud holding the ground wires to the right cylinder head.
Tighten the ground wire stud to 35 Nm (26 ft. lbs.).
23. Install the bolt and the ground strap to the rear of the right cylinder head.
Tighten the ground strap bolt to 35 Nm (26 ft. lbs.).
24. Position the engine wiring harness.
25. Install the engine wiring harness clips to the brackets.
26. Install the engine wiring harness clips to the front of the engine.
27. Connect the CKP sensor electrical connector (2).
28. Install the bolt and the battery negative cable (1).
Tighten the bolt to 17 Nm (13 ft. lbs.).
29. Install the engine wiring harness bracket bolt (3) to the generator mounting bracket.
Tighten the stud to 25 Nm (18 ft. lbs.).
30. Install the generator.
31. Connect the following electrical connectors:
^ The distributor (1)
^ The engine oil pressure sensor (2)
^ The KS sensor (3)
32. Connect the following electrical connectors:
^ The A/C compressor clutch (1), if equipped
^ The A/C compressor cutoff switch (5), if equipped
^ The TP sensor (2)
^ The IAC valve motor (3)
^ The ECT sensor (4)
33. Connect the following electrical connectors:
^ The fuel meter body (1)
^ The EVAP canister purge solenoid (2)
^ The MAP sensor (3)
34. Connect the following electrical connectors:
^ The ICM (1)
^ The ignition coil (2)
^ The EGR solenoid (3)
^ The generator (4)
35. Connect the power brake booster vacuum hose to the intake manifold.
36. Connect the vacuum hose for the A/C system, if equipped.
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.
37. 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.
38. Install a NEW accelerator control cable.
39. Install the cruise control cable, if equipped to the throttle shaft and the accelerator cable bracket.
40. Install the radiator.
41. Install the inlet and outlet radiator hose to the engine.
42. Connect the heater hoses to the engine.
43. Raise the vehicle.
44. Install the transmission.
45. Install the transmission cover.
Tighten the nut to 12 Nm (106 inch lbs.).
46. Install the starter.
47. Install the stud holding the bracket for the starter wiring harness and if equipped, the transmission oil cooler lines.
Tighten the bracket stud to 9 Nm (80 inch lbs.).
48. Connect the engine oil cooler pipes (RWD vehicle).
49. Connect the remote oil filter inlet and outlet hoses (Four Wheel Drive vehicle).
50. Install the exhaust pipe to the exhaust manifolds.
51. Install a NEW oil filter.
52. Install the underbody shields, if equipped.
53. Lower the vehicle.
54. Fill the engine with oil.
55. Fill the cooling system with coolant.
56. Connect the battery negative cable.
57. Install the air cleaner outlet duct from the throttle body.
58. Remove the PCV tube from the right valve rocker arm cover and the air cleaner outlet duct.
59. Recharge the air conditioning system, if equipped.
60. Install the hood.
61. Operate and test the engine. Refer to Engine Set-Up and Testing. Engine Set-Up and Testing