Engine Replacement

Engine Replacement

^ Tools Required
- J 41798 Engine Lift Bracket

Removal Procedure
1. Disconnect the negative battery cable.
2. Drain the engine oil.
3. Drain the cooling system.
4. Lower the vehicle.
5. Remove the hood assembly.
6. Remove the engine control module (ECM) and bracket.
7. Evacuate the air conditioning system.
8. Remove the air cleaner assembly.
9. Remove the upper tie bar.
10. Remove the radiator, A/C condenser, and cooling fan assembly.
11. Remove the accessory drive belt.
12. Remove the A/C compressor.
13. Remove the ground wire from the engine to the frame.
14. Remove the radiator hoses.
15. Remove the heater hoses.
16. Remove the surge tank assembly.





17. Remove the ignition coils.
18. Remove the generator mounting bracket.
19. Remove the intake manifold assembly.
20. Remove the electrical connector for the oil pressure sensor.
21. Relocate the engine wiring harness to the side and secure.
22. Remove the exhaust manifolds.
23. Remove the catalytic converters.
24. Remove the starter assembly.





25. Remove the ground wires (1, 2) and retaining bolts (3, 4) from the engine block.





26. Disconnect the electrical connector for the crankshaft position (CKP) sensor.





27. Disconnect the engine coolant temperature (ECT) sensor (1).





28. Disconnect the electrical connector (1) for the left knock sensor (3).





29. Disconnect the electrical connector (3) for the right knock sensor (2).
30. Disconnect the electrical connector for the camshaft sensor.





31. Remove the wiring harness from the front of the engine.
32. Remove the transmission assembly.





33. Remove the transmission cooling lines in front the side of the engine, automatic transmission only.





34. Remove the transmission lines from the rear of the engine, automatic transmissions only.
35. Remove, relocate, and secure the wiring harness at the rear of the engine.





36. Remove the left lower motor mounts retaining nuts.
37. Lower the vehicle.
38. Install the J 41798 to the engine.
39. Remove the right front shock.





40. Remove the motor mount to frame bolts.
41. Using the appropriate engine hoist, remove the engine assembly from the vehicle.
42. Install the engine assembly on the appropriate engine stand.

Installation Procedure
1. Remove the engine from the engine stand.
2. Position the engine in the vehicle.





3. Notice: Refer to Fastener Notice in Service Precautions.

Install the right motor mount to frame bolts.
^ Tighten the right motor mount to frame bolts to 100 Nm (74 ft. lbs.).
4. Install the right shock module.
5. Remove the hoist.
6. Remove the J 41798 from the engine.
7. Install the exhaust manifolds.
8. Install the transmission assembly.





9. Install the left lower motor mount retaining nuts.
^ Tighten the left motor mount nuts to 50 Nm (37 ft. lbs.).





10. Remove the wiring harness from the front of the engine.
^ Tighten the bolts to 12 Nm (106 inch lbs.).
11. Reconnect the electrical connector for the camshaft sensor.





12. Reconnect the CKP sensor.





13. Reconnect the electrical connector (3) for the right knock sensor (2).
14. Install the starter assembly (4).





15. Reconnect the electrical connector (1) for the left knock sensor (3).





16. Reconnect the electrical connector (1) for the left knock sensor (3).





17. Install the ground terminal bolt (2).
^ Tighten the bolts to 25 Nm (18 ft. lbs.).
18. Reconnect the ECT sensor (1).





19. Install the ground wires (1, 2) and retaining bolts (3, 4) to the engine block.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).





20. Install the transmission cooling lines in the front side of the engine, automatic transmission only.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).





21. Install the transmission lines from the rear of the engine, automatic transmissions only.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).
22. Install the catalytic converters.
23. Install the A/C compressor.
24. Lower the vehicle.
25. Connect the oil pressure sensor.
26. Install the intake manifold.
27. Position the engine wiring harness on the engine.
28. Install the generator mounting bracket.
29. Install the ignition coils.
30. Install the surge tank.
31. Install the heater hoses.
32. Install the accessory drive belt.
33. Install the radiator, A/C condenser, and cooling fan assembly.
34. Install the upper tie bar.
35. Install the radiator hoses.
36. Install the air cleaner assembly.
37. Raise the vehicle.
38. Reconnect the negative battery cable.
39. Fill the cooling system.
40. Fill the engine with motor oil.
41. Recharge the A/C system.
42. Install the hood assembly.