Removal and Replacement

REMOVAL - ENGINE ASSEMBLY

NOTE: Capture and store any residual fluid drainage, or leakage from ancillary components, in the appropriately marked containers.

1) Perform the fuel pressure release procedure.
2) Disconnect negative battery cable.
3) Drain the cooling system.





4) Remove the engine cover (Fig. 6).
5) Remove the cruise control servo.
6) Remove the radiator closure panel.
7) Remove the radiator core support.
8) Remove upper radiator hose.
9) Remove the radiator cooling fan assembly.
10) Remove air cleaner housing (Fig. 6).
11) Evacuate and recover the air conditioning.





12) Disconnect the throttle and cruise control cables from the throttle body (Fig. 7).
13) Disconnect the cruise control and power brake booster vacuum hoses at the engine.





14) Disconnect the transmission wiring harness from the solenoid pack, input and output sensors and the range sensor connectors (Fig. 8).
15) Disconnect the engine wiring harness grounds at the left inner frame rail.
16) Disconnect the transmission shift cable.





17) Disconnect the transmission cooler lines (Fig. 9).
18) Disconnect the engine block heater wiring connector and set aside (if equipped).
19) Disconnect the coolant reservoir hoses at the thermostat housing (Fig. 9).
20) Disconnect the heater hoses at the heater core (Fig. 9).
21) Disconnect upper radiator hose at the thermostat housing (Fig. 9).

NOTE: Use a brake pedal prop rod and depress the brake pedal to prevent excessive brake fluid loss when the brake system is opened.





22) Disconnect both front brake lines from the Hydraulic Control Unit (HCU) (Fig. 10).
23) Disconnect the air condition suction discharge hoses at the air conditioning compressor and plug the compressor openings to prevent contamination.
24) Disconnect lower radiator hose at the engine outlet and remove. (Fig. 9).
25) Disconnect A/C clutch electrical connector.
26) Disconnect oil pressure sending unit wiring harness connector.
27) Disconnect the electrical connectors at the generator.
28) Disconnect the fuel supply line at the fuel rail.
29) Disconnect the ignition harness connector at the intake manifold.
30) Raise and support the vehicle.
31) Remove the front wheels.
32) Remove left inner fender well.
33) Disconnect the engine harness from the powertrain control module (PCM).





34) Disconnect the left wheel speed sensor and retainers (Fig. 10).
35) Remove the left sway bar link at the front strut (Fig. 10).
36) Remove left drive axle nut (Fig. 10).
37) Remove both left steering knuckle pinch bolts (Fig. 10).
38) Separate the left steering knuckle from the strut and suitably support steering knuckle (Fig. 10).
39) Disconnect the negative battery cable from the transmission.
40) Remove the left fascia screws.
41) Remove right inner fender well.
42) Remove right fascia screws.
43) Disconnect the right wheel speed sensor and retainers (Fig. 10).
44) Remove right sway bar link at the front strut (Fig. 10).
45) Remove right drive axle nut (Fig. 10).
46) Remove right steering knuckle pinch bolts (Fig. 10).
47) Separate the right steering knuckle from the strut and suitably support the steering knuckle (Fig. 10).
48) Unplug fascia driving lamps (if equipped).
49) Remove front fascia.
50) Raise the vehicle.
51) Disconnect the starter wiring connectors and harness retainers.





52) Disconnect the exhaust manifold Oxygen sensor electrical connector (Fig. 11).
53) Disconnect the catalytic converter oxygen sensor electrical connector (Fig. 11).
54) Remove the exhaust system from the manifold and set aside.
55) Paint mark the rear driveshaft front and rear positions, then remove the drive shaft.
56) Remove the engine to transmission support plate.
57) Remove transmission inspection shield.
58) Remove the flex plate to torque converter bolts.

CAUTION: Secure the steering wheel to prevent rotation and possible damage to the steering column clock spring when coupling is separated.





59) Remove the lower steering column coupling pin with special tool 6831-A, and separate union. (Fig. 12).





60) Remove both lower engine mount nuts (Fig. 13).
61) Paint mark the front cradle to body location and position the engine cradle support under the vehicle (Fig. 13).
62) Lower the vehicle until just above the cradle support fixture (Fig. 13).
63) Align the cradle support dowels with the cradle access holes (Fig. 13).





64) Adjust engine support fixture to fit flush with the oil pan and adjust cradle support fixture arms to fit flush with cradle (Fig. 14).
65) Carefully lower the vehicle onto the cradle support fixture.
66) Remove the upper engine mount.

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

67) Carefully remove the front and rear cradle mounting bolts and raise the vehicle to separate the engine, transmission and cradle assembly from the vehicle.





68) Connect engine lifting brackets to engine (Fig. 15)
69) Separate the Power Transfer Unit (PTU), (if equipped).
70) Separate the engine and transmission from the engine cradle using the lifting brackets. (Fig. 15).
71) Separate the transmission from the engine.

INSTALLATION - ENGINE ASSEMBLY
1) Install transmission and power transfer unit (PTU) (if equipped), onto engine assembly.
2) Mount engine assembly onto cradle assembly.
3) Carefully position the engine cradle assembly under the vehicle.

CAUTION: While slowly lowering the body to the cradle assembly, constantly check to assure proper positioning and no damage occurs to other components or harnesses until union is made.

4) Lower the vehicle until the union is made between the cradle assembly and body taking care to align the cradle to body marks.
5) Install the cradle supporting bolts and tighten to 163 Nm (120 ft. lbs.).
6) Install upper engine mount, tighten bolt to timing cover to 54 Nm (40 ft. lbs.). Tighten bolt to right rail 68 Nm (50 ft. lbs.).
7) Slowly raise the vehicle off of the engine cradle support.
8) Insert drive axles into steering knuckles. Tighten nut to 244 Nm (180 ft. lbs.).
9) Align front steering knuckles with struts and install bolts. Tighten bolts to 244 Nm (180 ft. lbs.). (Fig. 10).
10) Install front wheel speed sensor wire support brackets to the struts (Fig. 10). Tighten bolts to 12 Nm (105 inch lbs.).
11) Connect both front wheel speed sensors to wiring harness.
12) Install brake line support bracket to cradle (Fig. 10). Tighten bolts to 12 Nm (105 inch lbs.).
13) Connect sway bar links to front struts (Fig. 10).
14) Raise vehicle.
15) Install the steering column coupler pin.
16) Connect the engine block heater (if equipped).
17) Connect negative battery cable to transmission.
18) Route engine wiring harness connector to PCM and connect.
19) Install inner fender wells.
20) Connect both front driving lights to the front fascia.
21) Install front fascia.
22) Install engine mount nuts and tighten to 101 Nm (75 ft. lbs.).
23) Install flex plate to torque converter bolts. Tighten bolts to 75 Nm (55 ft. lbs.).
24) Install transmission inspection shield. Tighten bolts to 12 Nm (105 inch lbs.).
25) Install engine to transmission support collar. Tighten bolts to 54 Nm (40 ft. lbs.).
26) Properly align and install the drive shaft.
27) Install exhaust system.
28) Connect exhaust manifold and catalytic converter oxygen sensor electrical connectors (Fig. 11).
29) Connect starter wiring and properly position harness wiring.
30) Install front wheels.
31) Lower the vehicle.
32) Connect both front brake lines to the brake system H.C.U. and tighten.
33) Connect the ignition harness connector at the intake manifold.
34) Connect the engine wiring harness and the ground wire on left frame rail
35) Connect transmission cooler lines to transmission (Fig. 9).
36) Connect transmission shift cable.
37) Connect transmission solenoid pack, input and output sensors and transmission range sensor.
38) Install the cruise control, power brake booster and fuel vapor vacuum hoses to the engine.
39) Connect throttle cable and cruise control cable to throttle body (Fig. 7).
40) Connect electrical connectors to generator.
41) Connect oil pressure sending unit wiring harness connector.
42) Connect A/C electrical connector.
43) Connect suction/discharge hose at air conditioning compressor.
44) Connect lower radiator hose to engine (Fig. 9).
45) Connect heater hoses to heater core (Fig. 9).
46) Connect coolant reservoir hose to thermostat housing (Fig. 9).
47) Connect the fuel line to the fuel rail.
48) Install cooling fan assembly.
49) Install radiator core support.
50) Install radiator close out panel.
51) Connect upper radiator hose (Fig. 9).
52) Install the cruise control servo.
53) Install air cleaner housing (Fig. 6).
54) Install the engine cover (Fig. 6).
55) Install new oil filter. Fill engine crankcase with proper oil to correct level.
56) Connect negative battery cable to battery.
57) Fill the cooling system.
58) Bleed brakes.
59) Start engine and run until operating temperature is reached and radiator fans cycle.
60) Evacuate and recharge air conditioning.
61) Check all fluid levels and properly fill.
62) Check front end alignment.