Steps 1 - 50
EngineSpecial Tools And Equipment:
Special Tool(s)
Removal
All vehicles
CAUTION: If the fuel rail is used as a leverage device, it can be damaged. Care must be taken when working around the fuel rail.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect the spring lock coupling.
3. Disconnect the battery cables.
4. Remove the nut and disconnect the ground wire.
5. Disconnect the electrical connector and detach the wiring harness retainers.
6. Lift the cover, remove the nut and disconnect the battery cable connector.
7. Drain the cooling system.
8. Recover the A/C system.
9. Disconnect the windshield washer hose.
10. NOTE: Mark the hinge locations for installation reference.
Remove the 4 bolts and the hood.
11. Remove the cooling fan and shroud.
12. Remove the power steering pump pulley.
13. Remove the air cleaner outlet pipe.
14. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
15. Remove the air cleaner assembly.
16. Disconnect the Powertrain Control Module (PCM) electrical connectors.
17. Release the wiring harness from the clips on the bulkhead.
18. Disconnect the transmission control wiring harness pin type retainers from the engine wiring harness.
19. Disconnect the Evaporative Emissions (EVAP) tube and position it aside.
20. Disconnect the vacuum hose.
21. Remove the bolt from the engine ground wire.
22. Disconnect the vacuum hose and the heater hose.
23. Disconnect the upper radiator hose and the heater hose.
24. Remove the bolts and position the heater hoses and bracket aside.
25. Disconnect the lower radiator hose at the coolant pump.
26. Disconnect the coolant hoses from the degas bottle.
27. NOTE: Cover the accumulator opening to prevent contamination.
Remove the nut and disconnect the A/C tube from the accumulator.
^ Discard the O-ring seal.
28. Remove the nut and disconnect the A/C tube from the condenser.
^ Discard the O-ring seal.
29. Disconnect the vacuum hoses.
30. Disconnect the A/C high pressure cut off switch electrical connector.
31. Remove the nut and disconnect the A/C tube from the condenser.
^ Discard the O-ring seal.
32. Disconnect the A/C tube from the retainer.
33. Remove the exhaust manifold to Exhaust Gas Recirculation (EGR) valve tube
1 Disconnect the exhaust manifold to EGR valve tube fittings.
2 Remove the exhaust manifold to EGR valve tube.
34. Remove the starter motor.
35. Remove the push pins and the lower air shroud panel.
36. Remove the nut and detach the battery cable retainer bracket.
4x4 vehicles
37. Install a suitable jack stand under the transfer case.
4x2 vehicles
38. WARNING: Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury.
Support the transmission with a transmission jack.
All vehicles
39. Remove the 2 bolts and position the RH heat shield aside.
40. NOTE: LH shown, RH similar.
Disconnect the 2 Heated Oxygen Sensor (HO2S) electrical connectors.
41. NOTE: RH shown, LH similar.
Disconnect the 2 catalyst monitor sensor electrical connectors.
42. Remove the RH heat shield bolts.
43. Remove the RH heat shield bolt and remove the heat shield.
44. Remove the LH heat shield bolt.
45. Remove the 2 nuts and the plastic shield on the right side of the crossmember.
46. NOTE: RH shown, LH similar.
Remove the 4 upper crossmember bolts.
47. NOTE: RH shown, LH similar.
Remove the 4 lower crossmember bolts.
4x2 vehicles
48. Remove the bolts and cable bracket from the transmission.
All vehicles
49. Remove the transmission support insulator nuts and remove the crossmember.
50. Remove the bolts, springs, flag nuts and separate the muffler from the converter.
^ Discard the gasket.
^ Discard the flag nuts.