Removal and Replacement

REMOVAL - ENGINE





1. Remove the engine cover (1).
2. Perform the Fuel System Pressure Release procedure.
3. Disconnect the battery negative cable.
4. Remove the air cleaner resonator and duct work as an assembly
5. Remove the cowl top panel.
6. Drain cooling system.
7. Remove the accessory drive belt.
8. Remove radiator fan shroud.





9. Remove the A/C compressor (3) with the lines attached. Secure compressor out of the way.





10. Remove the generator support bracket (1).





11. Remove generator (2).








12. Remove the intake manifold and IAFM as an assembly.
13. Remove the ground wires from the rear of each cylinder head.
14. Disconnect the heater hoses (1).

NOTE: It is not necessary to disconnect P/S hoses from pump, for P/S pump removal.

15. Remove the power steering pump and set aside.
16. Disconnect the fuel supply line.
17. Raise and support the vehicle on a hoist and drain the engine oil.





18. Remove the belly pan (2).





19. Remove engine front mount to frame nuts.
20. FOR AWD ONLY Mark the front driveshaft to the flange at both ends to ensure correct installation.
21. FOR AWD ONLY Remove front drive shaft fasteners from the differential and transfer case. Remove the driveshaft from the vehicle.
22. FOR AWD ONLY Remove the left (2) and right front drive axles.





23. FOR AWD ONLY Remove the differential support bracket (1) from the differential to the engine block.





24. FOR AWD ONLY Unbolt the differential (4) from the oil pan (3).
25. FOR AWD ONLY Rotate the differential (4) so the drive flange is facing forward and the oil pan side is facing up. Remove the differential out through the opening at the rear of the cradle.





26. FOR AWD ONLY Remove the intermediate shaft (2) from the oil pan (3).





27. Disconnect the transmission oil cooler lines from their retainers at the oil pan bolts.
28. Disconnect exhaust pipe at manifolds.
29. Disconnect the starter wires. Remove starter motor (1).





30. Remove the torque converter access cover (1).





31. Remove drive plate to converter bolts (1).





32. Remove transmission bell housing to engine block bolts (2).








33. Lower the vehicle.
34. Install engine lift fixture (2), special tool # 8984 and 8984-UPD (4).
35. Separate engine from transmission, remove engine from vehicle, and install engine assembly on a repair stand.

INSTALLATION - ENGINE





1. Install engine lift fixture (2) Special tool # 8984 and 8984-UPD (4).
2. Position the engine in the engine compartment.
3. Lower engine into compartment and align engine with transmission.
4. Mate engine and transmission and install two transmission to engine block mounting bolts finger tight.
5. Lower engine assembly until engine mount studs rest in frame perches.








6. Install remaining transmission to engine block mounting bolts (1, 2) and tighten.
7. Install and tighten engine mount to frame nuts.





8. Install drive plate to torque converter bolts (1).





9. Install the torque converter access cover (1).





10. Install the starter (1) and connect the starter wires.





11. FOR AWD). ONLY Install the intermediate shaft (2) to the oil pan (3). Torque fasteners to 28 Nm (21 ft. lbs).





12. FOR AWD). ONLY Install the front differential through the opening at the rear of the cradle, and attach to the oil pan.
13. FOR AWD). ONLY Fasten the differential (4) to the oil pan (3) Torque to 65 Nm (48 ft. lbs).





14. FOR AWD). ONLY Install the differential support bracket (1) to the differential and the engine block.





15. FOR AWD ONLY Install the left (2) and right front drive axles.
16. FOR AWD ONLY Install front drive shaft into the differential and transfer case.
17. Install exhaust pipe to manifold.
18. Lower the vehicle.





19. Remove engine lift fixture (2), special tool # 8984 and 8984-UPD (4).
20. Connect the fuel supply line.
21. Reinstall the power steering pump.








22. Connect the heater hoses(l, 1.).
23. Reconnect the ground wires to the rear of each cylinder head.
24. Install the intake manifold.





25. Install the generator (2), generator support bracket (1), and wire connections.








26. Install a/c compressor (3).
27. Install the accessory drive belt.
28. Install the radiator fan shroud.
29. Connect the radiator lower hose.
30. Connect the transmission oil cooler lines to the radiator.
31. Connect the radiator upper hose.





32. Install cowl top panel.
33. Install the air cleaner resonator and duct work.
34. Add engine oil to crankcase.
35. Fill cooling system.
36. Install the engine cover (1).





37. Connect battery negative cable.
38. Start engine and inspect for leaks.
39. Install the belly pan (2).
40. Road test vehicle.