Removal
Tools Required:
- Rotunda Powertrain Lift 014-00765
- Rotunda Powertrain Lift Adapter 014-00341
- Rotunda Engine Lifting Kit 014-00340
Removal
1. Disconnect negative and positive battery cables.
2. Remove engine appearance cover retaining bolt and nuts and remove cover from vehicle.
3. Disconnect IAT sensor connector and crankcase vent tube from engine air cleaner outlet tube assembly.
4. Completely loosen air cleaner outlet to throttle body bolt.
5. Loosen clamp on engine air cleaner outlet tube to engine air cleaner and disconnect tube.
6. Remove remaining bolt from support bracket clamp on RH cam cover to engine air cleaner outlet tube assembly.
7. Remove engine air cleaner outlet tube assembly and resonator assembly.
8. Drain cooling system at radiator. Disconnect coolant inlet hose at oil filter adapter connection to drain engine cooling system.
9. Remove windshield wiper module. Refer to Wiper and Washer Systems. Wiper and Washer Systems
10. Discharge air conditioning system. Refer to Heating and Air Conditioning. Heating and Air Conditioning
11. Remove cooling fan and shroud. Refer to Cooling System. Cooling System
12. Relieve fuel system pressure and disconnect fuel tubes. Refer to Fuel Delivery and Air induction. Fuel Delivery and Air Induction
13. Remove 42-pin connector from retaining bracket on LH fender well.
14. Disconnect 42-pin connector and position out of the way.
15. Remove power distribution box and disconnect generator B+ wiring connector from inside of box.
16. Disconnect engine harness connector from canister purge solenoid (CANP) assembly.
17. Disconnect accelerator and speed control cables from throttle body and also from accelerator cable bracket.
18. Disconnect canister purge vacuum line at throttle body connector.
19. Disconnect chassis vacuum supply hose at connection on cowl support.
20. Disconnect heater supply and return hoses at rear of RH cylinder head.
21. Disconnect upper radiator hose at coolant crossover tube.
22. Disconnect and drain coolant supply hose from coolant supply reservoir.
23. Remove power steering fluid return line from reservoir and drain. Remove power steering supply hose from reservoir at power steering pump. Remove reservoir retaining bolt and stud from LH coil bracket. Remove reservoir.
24. Remove upper transmission cooler line from radiator.
25. Install Rotunda Engine Lifting eyes 014-00340 or equivalent.
26. Disconnect A/C compressor lines and disconnect retaining clips from pump.
27. Partially raise vehicle on hoist.
28. Remove front wheels and tires.
29. Disconnect RH and LH ride height sensor wiring connectors.
30. Remove RH and LH brake caliper bolts. Remove brake calipers and support to vehicle using mechanic's wire.
31. Disconnect RH and LH upper control arms from spindles.
32. Raise vehicle.
33. Drain engine oil.
34. Remove exhaust system Y-pipe from both exhaust manifolds and resonator.
35. Disconnect ground strap fmm RH fender apron.
36. Disconnect power steering pressure line from steering rack at power steering pump connection.
37. Disconnect lower radiator hose at radiator and thermostat housing and remove hose.
38. Remove RH and LH lower strut to control arm bolts and nuts.
39. Disconnect transmission wiring harness and shift linkage.
40. Disconnect lower transmission cooler line from radiator.
41. Index driveshaft to rear axle companion flange.
42. Remove four bolts connecting driveshaft to rear axle companion flange. Support rear axle housing with jack stand.
43. Remove two nut and bolt assemblies retaining the front of the differential to the undercarriage.
44. Loosen rear differential bracket to body bolts and lower.
45. Slide driveshaft rearward until it is free of transmission extension housing.
46. Remove two retaining nuts from bottom front cover studs and remove starter cable.
47. Disconnect low oil level sensor connector and wiring harness from oil pan.
48. Disconnect starter motor and remove. Refer to Starting System. Starting System
49. Support subframe using Rotunda Powertrain Lift 014-00765 and Adapter 014-00341.
50. Remove rear transmission isolator retaining bolts.
51. Disconnect steering shaft coupler at rag joint.
52. Remove eight subframe bolts.
53. Lower engine and transmission assembly from vehicle.
54. Remove two motor mount through bolts.
55. Connect engine lifting spreader bar from Rotunda Engine Lifting Kit 014-00340 or equivalent, to lifting eyes on engine and lift engine and transmission assembly from subframe with hoist.
56. Lower engine and transmission. Support transmission on a level, stationary surface for transmission storage.
57. Remove transmission to cylinder block mounting bolts and separate engine from transmission/torque converter assembly.
58. Place engine on suitable work stand.
59. Remove engine lifting equipment.
60. Remove RH and LH engine insulators from cylinder block.
61. Remove RH and LH water jacket pipe plugs in cylinder block and drain balance of engine coolant. Reinstall pipe plugs.
62. Disconnect EGR valve to exhaust manifold tube from LH exhaust manifold connector, differential pressure feedback EGR (DPFE) hose connections and loosen EGR tube connector at EGR control valve. Remove EGR valve to exhaust manifold tube.
63. Remove eight nuts retaining LH exhaust manifold to cylinder head.
64. Remove exhaust manifold and exhaust manifold gaskets. Discard exhaust manifold gaskets.