Engine - Removal

REMOVAL

Special Tools:










1. Perform the fuel pressure release procedure Service and Repair.
2. Disconnect and isolate the negative battery cable.
3. Remove the hood Hood - Removal.
4. Remove the engine cover (1).





5. Remove the resonator (3) and the air cleaner body Air Cleaner Body - Removal.





6. Remove the electric vacuum pump (4) and mounting bracket (1) Removal.





7. Raise and support the vehicle Maintenance.
8. If equipped, remove the front skid plate, the front suspension skid plate, the transmission skid plate and the transfer case skid plate.
9. Drain the cooling system Service and Repair.
10. Drain the engine oil Service and Repair.
11. Remove the nut (1) and bolt (4) from the support brackets of the heater core return tube (3).
12. Remove the A/C compressor mounting stud (2).





13. Lower the vehicle.
14. Remove the nut (2) from the support bracket of the heater core return tube (3) and reposition the tube.





15. Remove the vapor purge tube (1) from the fuel purge solenoid (2) Service and Repair





16. Remove the PCV hose (1) from the PCV valve (2).





17. Remove the upper intake manifold (2) and insulator Intake Manifold - Removal





18. Disengage the clips (1), remove the make-up air tube (3) from the left cylinder head cover and reposition the transmission breather hose (2).





19. Disconnect the fuel supply hose (1) from the underbody fuel tube (2) Service and Repair





20. Remove the cooling fan module Cooling Fan - Removal.





21. Remove the accessory drive belt (3) Serpentine Accessory Drive Belt - Removal
22. Remove the generator (1) Generator - Removal.






NOTE: Right catalytic converter shown, left catalytic converter similar.

23. Disconnect the right and left upstream oxygen sensor connectors (4) from the main wire harness.
24. Loosen the lower catalytic converter flange bolts (3).
25. Remove the upper catalytic converter flange bolts (1) and reposition the right and left catalytic converters (2).






NOTE: Left engine mount shown, right engine mount similar.

26. Remove the bolts (1) and the engine mount heatshield (2) from both the left and right engine mounts.






NOTE: Mark the variable valve timing solenoid connectors (2) with a paint pen or equivalent so that they may be reinstalled in their original locations.

27. Disconnect the electrical connectors (2) from the variable valve timing solenoids on the right cylinder head.
28. Disengage the starter harness to main harness retainer (3).
29. Disengage two starter wire harness retainers (1) from the right cylinder head cover.





30. Disconnect the electrical connector (1) from the right Camshaft Position (CMP) sensor.
31. Disengage the main wire harness retainer (2) from the right cylinder head cover mounting stud.





32. Disengage four main wire harness retainers (1) from the right cylinder head cover.





33. Disconnect the oil pump solenoid electrical connector (2).
34. Disengage four wire harness retainers (1).
35. Remove the ground strap (3) from the right engine mount bracket.






NOTE: Mark the variable valve timing solenoid connectors (2) with a paint pen or equivalent so that they may be reinstalled in their original locations.

36. Disconnect the electrical connectors (2) from the left variable valve timing solenoids.
37. Disengage two starter wire harness retainers (1) from the left cylinder head cover.





38. Disconnect the A/C compressor electrical connector (1) and disengage the wire harness retainer (2) from the A/C compressor discharge line.





39. Disengage two starter wire harness retainers (1) from the upper intake manifold support brackets.
40. Disengage one main wire harness retainer (3) from the left cylinder head cover and two retainers (2) from the upper intake manifold support brackets.





41. Disconnect the Engine Coolant Temperature (ECT) sensor connector (3).
42. Disconnect the left Camshaft Position (CMP) sensor (5).
43. Disengage one main wire harness retainer (2) from the cylinder head cover and one main wire harness retainer (4) from the cylinder head cover mounting stud.
44. Disengage the main wire harness retainer (1) form the rear of the lower intake manifold.





45. Remove the remaining three bolts (1) and reposition the A/C compressor (2).





46. Remove the upper radiator hose (1) from the engine thermostat housing.





47. Remove the lower radiator hose (1) from the engine coolant pump housing.





48. Disconnect the heater core return hose (1).





49. Raise and support the vehicle Maintenance.
50. If equipped with AWD, remove the front axle (1) Removal.





51. Remove the starter Starter - Removal.
52. Disengage the starter wire harness retainer (2) and the main wire harness retainer (1) from the engine block.





53. Reinstall the left engine mount bracket (1) and isolator (4) assembly with four bolts (5) and two bolts (3). Tighten all bolts to 61 Nm (45 ft. lbs.).





54. Unclip the transmission cooler line retainer (1) from the upper oil pan flange.





55. Push back the heatshield (1) from the crankshaft position (CKP) sensor.





56. Disconnect the main wire harness from the Crankshaft Position (CKP) sensor (3).
57. Disengage one main wire harness retainer (1) from the engine block and one main wire harness retainer (2) from the right engine mounting bracket.
58. Disconnect and reposition the power cord from the engine block heater (if equipped).





59. Rotate the crankshaft in a clockwise direction until the torque converter bolts (1) are accessible through the starter mounting. Remove the six torque converter bolts (1).






NOTE: If equipped with AWD, the rear of the engine must be lowered in order to access the upper transmission to engine bolts.

60. If equipped with AWD, support the transmission with a suitable jack, remove three crossmember brace bolts (1), six crossmember bolts (2) and adjust the jack to lower the rear of the engine.





61. Loosen the bolt (1) securing the transmission fluid level indicator tube (2) to the transmission housing.





62. Remove four upper transmission to engine bolts (1).





63. Disconnect the main harness from the engine injection/ignition harness (1) at the rear of the left cylinder head.
64. Disconnect the main harness from the engine oil pressure/temperature harness (2) at the rear of the left cylinder head.





65. If equipped with AWD, raise the rear of the engine, reinstall six crossmember bolts (2) and three crossmember brace bolts (1). Tighten all bolts to 55 Nm (41 ft. lbs.).





66. Remove the bolt (2) and the torque converter dust shield (3).
67. Remove the side engine to transmission bolt (1).





68. Remove two rubber plugs (1) covering the rear oil seal retainer flange bolts.





69. Remove four transmission to the engine oil pan bolts (1).





70. Lower the vehicle.
71. Remove the bolt (1) and remove the oil level indicator (2).





72. Remove the bolt (2) and the heater core supply tube (1).





73. If equipped with AWD, disengage the transfer case vent hose retainer (1) from the upper intake manifold support bracket (2).





74. Remove the bolts (2) and remove the LH upper intake manifold support brackets (1).





75. Install the Driver Side Engine Lifting Bracket (1) on the LH cylinder head with bolts (2) provided with the Engine Lifting Bracket. Tighten the bolts to 21 Nm (15 ft. lbs.).





76. Install the Passenger Side Engine Lifting Bracket (1) on the RH cylinder head with bolts (2) provided with the Engine Lifting Bracket. Tighten the bolts to 21 Nm (15 ft. lbs.).





77. Reposition the starter wire harness and the main wire harness to the rear of the engine compartment.
78. Position a load-leveling lifting sling (2), such as OTC(R) 4305 Engine Load Leveler or equivalent, between the engine lifting brackets (3) and an engine hoist (1).






NOTE: Left engine mount shown, right engine mount similar.

79. Support the transmission with a suitable jack.
80. Remove both the left and right engine mount nuts (1).

CAUTION: While slowly separating the engine from the vehicle, constant checks must be made to assure proper positioning and that no damage to other components or wiring harnesses occur during separation.

81. Carefully remove the engine from the engine bay area.
82. If required, remove the following components for installation on the replacement engine:
- LH engine mount bracket
- RH engine mount bracket
- Accessory drive belt tensioner
- Upper intake manifold support bracket
- Heater core return tube
- Block heater (if equipped)