Engine: Service and Repair

REMOVAL

NOTE: The engine assembly can be removed through the front of the engine compartment without the transmission attached.

WARNING: Residual pressure remains in fuel system after engine is shut off. This could result in injury or fire when fuel lines are disconnected. Disconnect inertia fuel shutoff switch and crank engine until fuel in lines is used up.

1. Open the hood and disconnect the battery negative cable.
2. Recover refrigerant from air conditioning system.

NOTE: Determine which type of air conditioning refrigerant is used in the vehicle to be serviced and follow the procedure for that specific refrigerant.

3. Remove the radiator grille and inside engine cover.
4. Remove the air cleaner outlet tube and the engine air cleaner.
5. Disconnect and remove the A/C condenser core.
6. Position a drain pan under the oil pan and drain the engine oil.
7. Position a drain pan, disconnect and remove the power steering return hose.
8. Remove the front bumper cover.
9. Position a drain pan, disconnect and remove the transmission oil cooler.
10. Drain the radiator and remove the upper radiator hose and lower radiator hose.
11. Disconnect the transmission oil cooler inlet tube and oil cooler tube from the radiator.
12. Disconnect the fan shroud and position it over the fan blade.
13. Remove the radiator.
14. Using a wrench, lift drive belt tensioner pulley and remove the drive belt.
15. Remove the radiator air deflector.
16. Remove the hood and the center hood latch support.

Alternator Removal/Installation:

17. Disconnect and remove the alternator.
18. Disconnect and remove the A/C compressor.
19. Remove the oil fill pipe.
20. From inside the vehicle, remove the engine cover.
21. Remove the accelerator control splash shield.
22. At the power steering pump, remove the power steering pressure hose and power steering return hoses.

Power Steering Pump Removal/Installation:

23. Remove the power steering pump and A/C compressor mounting bracket.
24. Remove the transmission oil filler tube and oil level indicator.
25. Remove the engine oil level indicator and oil level indicator tube.
26. Disconnect the dual converter Y pipe from the exhaust manifolds.
27. Disconnect and remove the starter motor.
28. Remove the converter-to-flywheel bolts through the starter motor opening in the converter housing.

Transmission Cooling Lines And Bracket:

29. Remove the transmission oil cooler line bracket retaining bolt.
30. Remove the engine mount to frame bolts (left and right sides).
31. Remove the torque converter housing to engine bolts, except the upper bolts.
32. Remove the left front engine support insulator from the engine.

Upper Torque Converter Housing Bolts:

33. Remove the upper torque converter housing bolts.
34. Disconnect the transmission and transfer case electrical connectors.
35. Using Disconnect Tools D87L-9280-A and D87L-9280-B, disconnect the fuel supply and return lines where the engine supply and return tubes connect to the chassis fuel lines to the left of the engine near the frame.
36. Disconnect the accelerator cable and accelerator shaft bracket and position aside.
37. Disconnect the upper and lower heater water hoses.
38. Disconnect the engine vacuum lines from the fuel vapor canister, lower intake manifold and the upper intake manifold vacuum outlet fitting and cap.
39. Remove the spark plug wires from the ignition coil assembly and disconnect and remove the ignition coil assembly, with ignition coil mounting strap.
40. Disconnect the electrical connector from the throttle body throttle position sensor.
41. Remove the throttle body and upper intake manifold as an assembly.
42. Disconnect the fuel charging wiring connectors at both left front and right rear of engine.
43. Install engine lifting brackets on the right front and left rear of the engine and remove from the vehicle.

INSTALLATION

NOTE: To facilitate engine-to-transmission installation, make two guide studs by cutting the heads off two M10 x 70 mm bolts and grinding a screwdriver slot in the end of each bolt on the un-threaded end.

WARNING: Do not operate engine with hood open until fan has been first checked for possible cracks and separation.

1. Position the engine in the vehicle and remove the engine lifting brackets.
2. Connect the fuel charging wiring main connectors.
3. Install the throttle body and upper intake manifold.
4. Install the ignition coil and ignition coil mounting strap, and connect the spark plug wires and the coil assembly wiring connector.
5. Connect the electrical connector for the throttle position sensor.
6. Connect the upper and lower heater water hoses.
7. Connect the engine vacuum lines to the fuel vapor canister, lower intake manifold and the upper intake manifold vacuum outlet fitting and cap.
8. Connect the accelerator cable and accelerator shaft bracket.
9. Connect the fuel supply and return lines where engine supply and return tubes connect to the chassis fuel lines to the left of the engine near the frame.
10. Install the left front engine support insulator.
11. Install the converter housing to engine bolts. Connect the transmission electrical connectors
12. Install the engine mount to frame bolts (left and right sides).
13. Install the transmission oil cooler line bracket retaining bolt.
14. Through the starter motor opening in the converter housing, install the converter-to-flywheel bolts.
15. Install the starter motor and connect the starter motor wires. Connect the exhaust system to the manifolds.
16. Install the transmission oil filler tube and oil level indicator.
17. Install the engine oil level indicator and oil level indicator tube.
18. Install the power steering pump and A/C compressor mounting bracket.
19. Install the power steering pressure hose and power steering return hose at the power steering pump.
20. Install the accelerator control splash shield.
21. Install the engine oil fill pipe.
22. From inside the vehicle, install the engine cover.
23. Install and connect the A/C compressor.
24. Install and connect the alternator.
25. Install the hood and center hood latch support.
26. Install the right front radiator air deflector.
27. Install drive belt.
28. Install the radiator.
29. Install the radiator fan shroud.
30. Connect the oil cooler inlet tube and oil cooler outlet tube at the radiator.
31. Install the upper radiator hose and lower radiator hose, fill and bleed the cooling system.
32. Install the transmission oil cooler.
33. Install the front bumper cover.
34. Install and connect the power steering return hose.
35. Refill the engine with the recommended quantity and quality of engine oil.
36. Install and connect the A/C condenser core.
37. Install the engine air cleaner and air tube.
38. Install the radiator grille and inside engine cover.
39. Connect the battery ground cable.

NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.

40. Recharge air conditioning.
41. Start engine and check for leaks.