Removal
ENGINE REMOVAL / INSTALLATION - 4.0LRemoval
All vehicles
1. Disconnect the negative battery cable.
Caution: If the fuel supply manifold is used as a leverage device, damage can occur to the supply manifold. Care must be taken when working around the fuel supply manifold.
2. Disconnect the spring lock couplings.
Note: Mark the hinge locations for installation reference.
3. Remove the hood.
4. If the vehicle is equipped with A/C, discharge and recover the A/C system.
5. Disconnect the mass air flow (MAF) sensor electrical connector.
6. Remove the fan blade.
7. Remove the air cleaner housing cover.
8. Remove the radiator.
9. Disconnect the accelerator and cruise control cables.
1 Detach the accelerator and cruise control cables from the throttle body.
2 Detach the accelerator and cruise control cables from the bracket and position the cables aside.
10. If the vehicle is equipped with A/C, disconnect the A/C field coil electrical connector.
11. If the vehicle is equipped with A/C, disconnect the A/C high pressure switch electrical connector.
12. If the vehicle is equipped with A/C, remove the bolt and position the A/C hoses aside.
13. Remove the accessory drive belt.
14. Disconnect the high pressure hose from the lower power steering pump fitting.
Note: The battery is removed for clarity.
15. Disconnect the power steering return hose from the power steering fluid reservoir.
16. Remove the accessory bracket bolts and the bracket, the A/C compressor, if equipped, the power steering pump and the power steering reservoir as an assembly.
17. Disconnect the generator electrical connections.
18. Disconnect the wiring harness retainer and position generator wiring away from the engine.
19. Loosen the bolt and disconnect the engine wiring harness electrical connector.
20. Remove the engine wiring harness retainer nut.
21. Loosen the bolt and disconnect the powertrain control module (PCM) electrical connector.
22. Remove the retainer from the PCM ground wire and position the wiring harness aside.
23. Remove the retainer from the engine ground wire.
24. Disconnect the brake booster vacuum hose.
Early build vehicles
25. Disconnect the vapor hose.
26. Disconnect the vapor hose and pin-type retainer. Remove the vapor hose.
Late build vehicles
27. Disconnect the vapor hose from the intake manifold.
28. Disconnect the vapor hose from the purge valve and remove the hose.
All vehicles
29. Remove the crankcase breather hose and disconnect the two vacuum hoses (one shown).
Note: Heater hose will be removed with engine.
30. Disconnect the heater hose.
31. Disconnect the heater hose.
Vehicles equipped with an automatic transmission
32. Remove the transmission level indicator tube nut.
All vehicles
33. Remove the starter motor.
Note: 2WD shown, 4WD similar.
34. Remove the bolt and the engine wiring harness bracket. Disconnect the oil pressure sensor electrical connector
Vehicles equipped with an automatic transmission
35. Disconnect the transmission control and input shaft electrical connectors. Remove the wiring harness pin-type retainer.
36. Disconnect the output shaft speed (OSS) sensor and digital transmission range (TR) sensor electrical connectors.
37. Remove the bolt and position the transmission cooling tube bracket aside.
38. Remove the four torque converter nuts.
Vehicles equipped with a manual transmission
39. Disconnect the reversing lamp switch electrical connector.
40. Disconnect the following:
1 Disconnect the OSS sensor electrical connector.
2 Detach the heated oxygen sensor (HO2S) electrical connector from the bracket.
All vehicles
41. Drain the engine oil.
42. Install the oil drain plug.
43. Remove the oil filter.
44. Disconnect the RH HO2S electrical connector.
45. Disconnect the RH HO2S electrical connector.
46. Disconnect the LH HO2S electrical connector.
47. Remove the Y-pipe-to-catalytic converter nuts, bolts and gasket.
48. Remove the nuts.
49. Remove the nuts and the exhaust pipe.
50. Disconnect the wiring harness electrical connector located on the frame.
51. Release the transmission/transfer case portion of the wiring harness from any routing clips or pin-type retainers.
52. Route the transmission/transfer case portion of the wiring harness to the top of the engine.
53. If equipped with A/C, remove the A/C tube bracket nut and position it aside.
Note: Automatic transmission shown, manual transmission similar.
54. Remove the eight bolts.
55. Remove the RH engine insulator nuts.
56. Remove the LH engine insulator nuts.
57. Install the left side lifting bracket
58. Install the right side lifting bracket.
59. Install the spreader bar to the lifting eyes.
60. Position a floor jack under the bell housing of the transmission.
61. Attach a floor crane to the Spreader Bar and remove the engine.