Removal and Replacement

REMOVAL - ENGINE
1. Disconnect both battery negative cables.
2. Recover A/C refrigerant (if A/C equipped).
3. Raise vehicle on hoist.
4. Drain engine coolant.
5. Remove engine oil drain plug and drain engine oil.
6. Lower vehicle.
7. Remove radiator upper hose.
8. Remove the cooling fan shroud-to-radiator mounting bolts.
9. Remove viscous fan/drive assembly. Remove the cooling fan and shroud together.





10. Disconnect the coolant recovery bottle hose from the radiator filler neck and remove bottle from fan shroud (Fig. 2).
11. Disconnect heater core supply and return hoses from the cylinder head fitting and coolant pipe.
12. Raise vehicle on hoist.
13. Remove transmission and transfer case (if equipped.).





14. Disconnect exhaust pipe from turbocharger extension pipe (Fig. 3).
15. Remove starter motor.
16. Disconnect A/C suction/discharge hose from the rear of the A/C compressor.
17. Lower vehicle.
18. Disconnect lower radiator hose from radiator outlet.
19. Automatic Transmission models: Disconnect transmission oil cooler lines from radiator using special tool #6931.
20. Remove radiator.
21. Remove upper radiator support panel.
22. Remove front bumper.
23. If A/C equipped, disconnect A/C condenser refrigerant lines.
24. Disconnect charge air cooler piping.
25. Remove the two charge air cooler mounting bolts.
26. Remove charge air cooler (and A/C condenser if equipped) from vehicle.
27. Disconnect engine block heater connector.
28. Disconnect A/C compressor electrical connectors.
29. Remove the passenger battery ground cable from the engine block.
30. Disconnect power steering pump pressure and return lines.
31. Remove accelerator linkage cover.





32. Leaving all cables attached, remove Accelerator Pedal Position Sensor assy. (APPS) (Fig. 4) from cylinder head bracket and secure out of the way.





33. Disconnect APPS connector (Fig. 5).





34. Disconnect vacuum pump supply hose (Fig. 6).
35. Disconnect the engine harness and ground cable from the PDC.





36. Disconnect the fuel supply and return hoses (Fig. 7).
37. Remove the cylinder head cover.





38. Remove the #5 and #6 cylinder intake and exhaust rocker arms and pedestals (Fig. 8). Note the original location for re-assembly.
39. Loosen but do not remove engine mount through bolts and nuts.
40. Attach chain across engine lift brackets.
41. Lift engine up and out of engine compartment.
42. Install engine to suitable engine stand.

INSTALLATION - ENGINE
1. Install the engine with the cylinder head cover and the #5 and 6 rocker arm assemblies removed.
2. Lower the engine into the compartment and install the engine mount through bolts and nuts.
3. Tighten the mount through bolts and nuts to 88 Nm (65 ft. lbs.) torque.
4. Remove the engine lifting device.
5. Install the #5 and #6 rocker arms and pedestals in their original locations (Fig. 8). Torque the mounting bolts to 36 Nm (27 ft. lbs.) torque.
6. Install the cylinder head cover and gasket.
7. Connect the fuel supply and return hoses (Fig. 7).
8. Connect the engine harness connector and ground cable to the PDC.
9. Connect the vacuum pump supply hose.
10. Connect the APPS connector (Fig. 5).
11. Install the APPS assembly bracket to the cylinder head bracket.
12. Install the throttle linkage cover.
13. Connect the power steering pressure and return lines.
14. Connect the passenger battery ground cable to the engine block. Tighten the bolt to 77 Nm (57 ft. lbs.) torque.
15. Connect the engine block heater connector.
16. Connect the a/c compressor electrical connectors.
17. Install the charge air cooler and a/c condenser (if a/c equipped). Install and tighten the charge air cooler mounting bolts to 2 Nm (17 inch lbs.) torque.
18. Connect the charge air cooler piping. Torque all clamps to 8 Nm (72 inch lbs.) torque.
19. Connect the a/c refrigerant lines to the a/c condenser (if equipped).
20. Install the front bumper.
21. Install the radiator upper support panel.
22. Install the radiator.
23. Connect the transmission quick-connect oil cooler lines to the radiator. Push together until an audible "click" is heard. Verify connection by pulling apart.
24. Raise vehicle.
25. Connect a/c compressor suction/discharge hose (if a/c equipped).
26. Install the radiator lower hose and clamps.
27. Install the starter motor.
28. Install the transmission and transfer case (if equipped).
29. Connect the exhaust pipe to the turbocharger elbow (Fig. 3). Torque the bolts to 34 Nm (25 ft. lbs.) torque.
30. Connect the transmission auxiliary oil cooler lines (if equipped).
31. Lower the vehicle
32. Connect the heater core supply and return hoses.
33. Install the cooling fan and shroud at the same time.
34. Install the coolant recovery bottle to the fan shroud (Fig. 2) and connect the hose to the radiator filler neck.
35. Install the windshield washer bottle to the fan shroud and connect the pump supply hose and electrical connections.
36. Install the radiator upper hose and clamps.
37. Change oil filter and install new engine oil.
38. Fill cooling system with coolant.
39. Connect battery negative cables.
40. Perform the fuel line air bleed procedure.
41. Start engine and inspect for engine oil, coolant, and fuel leaks.