Steps 1 - 40

Engine Replacement

Tools Required
- J25034-C Power Steering Pump Pulley Remover
- J42188 Ball Joint Separator
- J39580 Engine Support Table
- J39580-500 Engine Support Table Top
- J41798 Engine Lifting Brackets
- J42203 Driveline Support
- J36221 Hydraulic Clutch Line Separator
- J25033-C Power Steering Pump Pulley Installer
- J36660-A Torque Angle Meter

Removal Procedure

Important: The steps in the following procedure are in a specific order. Follow these steps in this order and do not ignore any details or vehicle damage may occur.





1. Recover the Air Conditioning (A/C) refrigerant.
2. Remove the radiator.
3. Remove the break pressure modulator valve (BPMV) bracket.
4. Reposition the brake pipes.
5. Remove the accessory drive belt.
6. Remove the right fuel injection rail cover.
7. Relieve the fuel system pressure.
8. Disconnect the EVAP emission canister purge hose at the fuel line.
9. Remove the fuel feed hose.

Important: Cap the hoses and inlets when separating the cooling system components, this prevents dirt and other contaminants from entering the cooling system.





10. Remove the radiator hoses from the water pump.





11. Remove the heater hoses from the water pump.





12. Disconnect the following electrical connectors from the engine:
- The fuel injectors (1)
- The ignition coil main harness connectors
- The Evaporative Emission (EVAP) solenoid (2)
- The electric throttle motor (3)
- The Throttle Position (TP) sensor
- The Engine Coolant Temperature (ECT) sensor
- The A/C compressor

13. Remove the generator.





14. Remove the power brake booster vacuum hose.





15. Remove the intermediate steering shaft bolt (to steering gear).
16. Remove the intermediate steering shaft from the steering gear and position it to the left onto the frame rail.





17. Disconnect the secondary Air Injection (AIR) pump hose from the AIR pipe.
18. Remove the front tires and wheels.
19. Remove the catalytic converter.





20. Remove the driveline tunnel close-out panel bolts.
21. Remove the driveline tunnel close-out panel.
22. Remove the starter motor.





23. Disconnect the Crankshaft Position (CKP) sensor electrical connector (1).
24. Disconnect the oil level sensor electrical connector (2).
25. Disconnect the right Heated Oxygen Sensor (HO2S) electrical connector.





26. Remove the A/C compressor and condenser hose bolt (at compressor).
27. Separate the A/C compressor and condenser hose from the A/C compressor.





28. Disconnect the engine oil temperature sensor (3) electrical connector.
29. Disconnect the left H02S electrical connector.
30. Remove the ground strap bolt.
Remove the ground straps (1 and 2) from the engine block.





31. Disconnect the wheel speed sensor electrical connectors.
32. If equipped with Real Time Damping (RTD) disconnect the following electrical connectors:
- Shock absorber damper
- Position sensor pigtail

33. Unclip the transmission wire harness from the crossmember.
34. Disconnect the Electronic Variable Orifice (EVO) control connector clips from the crossmember.





35. Remove the transmission harness clip bolts from the engine block.
36. Unclip the transmission wire harness from the engine wire harness.
37. Remove the stabilizer shaft.





38. Loosen, do not remove, the steering knuckle nut (2) from the lower control arm ball stud.
39. Install the J42188 between the steering knuckle and the lower control arm ball stud.
40. Tighten the nut on the J42188 until the steering knuckle and the looter control arm ball stud separate.