Part 1 of 2
Engine
Special Tool(s)
Removal
All vehicles
CAUTION: If the supply manifold is used as a leverage device, damage can occur to the supply manifold. Care must be taken when working around the fuel supply manifold.
1. Disconnect the fuel tube spring lock coupling.
2. Remove the nut and disconnect the ground wire.
3. Disconnect the electrical connector and detach the wiring harness retainers.
4. Lift the cover, remove the nut and disconnect the battery cable connector.
5. Drain the cooling system.
6. Recover the A/C system.
7. Disconnect the windshield washer hose.
8. NOTE: Mark the hinge locations for installation reference.
Remove the four bolts and the hood.
9. Remove the cooling fan and shroud.
10. Remove the power steering pump pulley.
11. Remove the air cleaner outlet pipe.
12. Disconnect the mass air flow (MAF) sensor electrical connector.
13. Remove the air cleaner assembly.
14. Disconnect the powertrain control module (PCM) electrical connectors.
15. Release the fuel charging wiring harness from the clips on the bulkhead.
16. Disconnect the transmission control wiring harness pin-type retainers from the fuel charging wiring harness.
17. Disconnect the evaporative emissions (EVAP) return tube and position it aside.
18. Disconnect the vacuum hose.
19. Remove the halt from the engine ground wire.
20. Disconnect the vacuum hose and the heater hose.
21. Disconnect the upper radiator hose and the heater hose.
22. Remove the bolts and position the heater hoses and bracket aside.
23. Disconnect the lower radiator hose at the coolant pump.
1. Release the clamp.
2. Disconnect the radiator hose.
24. Disconnect the coolant hoses from the degas bottle.
25. NOTE: Cover the accumulator opening to prevent contamination.
Remove the nut and disconnect the A/C tube from the accumulator.
^ Discard the O-ring seal.
26. Remove the nut and disconnect the A/C tube from the condenser.
27. Disconnect the vacuum hoses.
28. Disconnect the A/C high-pressure cut-off switch electrical connector.
29. Remove the nut and disconnect the A/C tube from the condenser.
^ Discard the O-ring seal.
30. Disconnect the A/C tube from the retainer.
31. Remove the EGR valve tube.
1. Disconnect the EGR tube fittings.
2. Remove the EGR tube.
32. Remove the starter.
33. Remove the pushpins.
34. Remove the nut and detach the battery cable retainer bracket.
4x4 vehicles
35. Install a suitable jack stand under the transfer case.
4x2 vehicles
36. WARNING: Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury.
Support the transmission with a transmission jack.
All vehicles
37. Remove the two bolts and position the RH heat shield aside.
38. NOTE: LH shown, RH similar.
Disconnect the two heated oxygen sensor (HO2S) electrical connectors.
39. NOTE: RH shown, LH similar.
Disconnect the two catalyst monitor sensor electrical connectors.
40. Remove the RH heat shield bolts.
41. Remove the RH heat shield bolt and remove the heat shield.
42. Remove the LH heat shield bolt.
43. Remove the two nuts and the plastic shield on the right side of the crossmember.
44. NOTE: RH shown, LH similar.
Remove the four lower crossmember bolts.
45. NOTE: RH shown, LH similar.
Remove the four lower crossmember bolts.
4x2 vehicles
46. Remove the bolts and cable bracket from the transmission.
All vehicles
47. Remove the transmission support insulator nuts earl remove the crossmember.
48. Remove the bolts, springs, flag nuts and separate the muffler from the converter.
^ Discard the gasket.
^ Discard the flay nuts.
49. NOTE: LH shown, RH similar.
Remove the four converter to manifold nuts.
50. NOTE: The assistance of another technician may be required.
Remove the transmission-mounted exhaust hanger, the three-way converter system and the RH heat shield.
1. Remove the bolt and the converter assembly.
2. If required, remove the second bolt and mount.
51. Disconnect the shift cable and remove the bracket.
52. Position the manual shift lever out of PARK.
4x4 vehicles
53. Index-mark the front axle pinion flange and the front driveshaft.
54. Index-mark the front output shaft assembly and the front driveshaft constant velocity (CV) joint.
55. Remove and discard the bolts and washers.
56. Remove and discard the bolts and universal joint retainers.
57. CAUTION: Always disconnect the front driveshaft from the transfer case first. Otherwise, the weight of the driveshaft can pinch the boot and cause the boot to tear.
CAUTION: Tape the bearing cups to the driveshaft to prevent them from falling off the spider.
Remove the front driveshaft.