Removal Procedure
Engine Replacement
^ Tools Required
- J 25034-C Power Steering Pump Pulley Remover
- J 42188 Ball Joint Separator
- J 39580 Engine Support Table
- J 39580-500 Engine Support Table Top
- J 41798 Engine Lifting Brackets
- J 42203 Driveline Support
- J 36221 Hydraulic Clutch Line Separator
- J 25033-C Power Steering Pump Pulley Installer
- J 36660-A Torque Angle Meter
Removal Procedure
Important: The steps in the following procedure are in a specific order. Follow these steps in this order and do not ignore any details.
1. Recover the air conditioning (A/C) refrigerant. Refer to Refrigerant Recovery and Recharging.
2. Remove the radiator.
3. Remove the break pressure modulator valve (BPMV) bracket.
4. Reposition the brake pipes.
5. Remove the accessory drive belt.
6. Remove the right fuel injection rail cover.
7. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
8. Disconnect the evaporative emission (EVAP) canister purge hose at the fuel line.
9. Remove the fuel feed hose.
10. Important: Cap the hoses and inlets when separating the cooling system components, this prevents dirt and other contaminants from entering the cooling system.
Remove the radiator hoses from the water pump.
11. Remove the heater hoses from the water pump.
12. Disconnect the following electrical connectors from the engine:
^ The fuel injectors (1)
^ The ignition coil main harness connectors
^ The EVAP solenoid (2)
^ The electric throttle motor (3)
^ The throttle position (TP) sensor
^ The engine coolant temperature (ECT) sensor
^ The A/C compressor
13. Remove the generator.
14. Remove the power brake booster vacuum hose.
15. Remove the intermediate steering shaft bolt to the steering gear.
16. Remove the intermediate steering shaft from the steering gear and position it to the left onto the frame rail.
17. Remove the front tires and wheels.
18. Remove the catalytic converter.
19. Remove the driveline tunnel close-out panel bolts.
20. Remove the driveline tunnel close-out panel.
21. Remove the starter motor.
22. Disconnect the crankshaft position (CKP) sensor electrical connector (1).
23. Disconnect the oil level sensor electrical connector (2).
24. Disconnect the right heated oxygen sensor (HO2S) electrical connector.
25. Remove the A/C compressor and condenser hose bolt at the compressor.
26. Separate the A/C compressor and condenser hose from the A/C compressor.
27. Disconnect the engine oil temperature sensor (3) electrical connector.
28. Disconnect the left HO2S electrical connector.
29. Remove the ground strap bolt. Remove the ground straps (1 and 2) from the engine block.
30. Disconnect the wheel speed sensor electrical connectors.
31. If equipped with real time damping (RTD) disconnect the following electrical connectors:
^ Shock absorber damper
^ Position sensor pigtail
32. Unclip the transmission wire harness from the crossmember.
33. Disconnect the electronic variable orifice (EVO) control connector clips from the crossmember.
34. Remove the transmission harness clip bolts from the engine block.
35. Unclip the transmission wire harness from the engine wire harness.
36. Remove the stabilizer shaft.
37. Loosen, do not remove, the steering knuckle nut (2) from the lower control arm ball stud.
38. Install the J 42188 between the steering knuckle and the lower control arm ball stud.
39. Tighten the nut on the J 42188 until the steering knuckle and the lower control arm ball stud separate.
40. Disconnect the antilock brake system (ABS) electrical connector clips from the crossmember, if equipped.
41. Remove the front transverse leaf spring.
42. Disconnect the automatic transmission fluid cooler pipe clip from the front of the engine oil pan, if equipped.
43. Disconnect the front automatic transmission fluid cooler pipes from the rear pipes.
44. Disconnect the automatic transmission cooler pipe clip at the right transmission cover, if equipped.
45. Notice: Refer to Fastener Notice in Service Precautions.
Important: Failure to use the minimum fastener length specified will prevent proper retention of the propeller shaft during disassembly.
With automatic transmission vehicles, use the following steps:
1. Remove the 2 driveline support hole plug bolts.
2. Install a M10.0-1.5 x 55 mm bolt or longer in each plug location.
^ Tighten the M10 bearing support bolts to 35 Nm (26 ft. lbs.).
46. If equipped with an automatic transmission, remove the flywheel housing plug.
47. If equipped with an automatic transmission perform the following:
0. Orientate the prop shaft hub clamp for access to the bolt (1).
1. Position the clamp bolt (1) facing downward.
2. Loosen the prop shaft hub clamp bolt (1).
48. Remove bolts attaching the transmission wire harness bracket to the flywheel housing.
49. Remove the transmission wire harness from its mounting location, rearward toward the driveline support.
50. Lay the harness on the driveline support. Secure if necessary.
51. Important: The weight of the engine should never be supported by the J 42203 .
Install the J 42203 to the close-out panel flange.
52. If equipped with a manual transmission, perform the following:
0. Unclip the clutch actuator hose from the clutch actuator hose clip.
1. Using the J 36221, depress the white circular release ring on the actuator hose and simultaneously pull lightly on the master cylinder hose to disconnect.
2. Protect both ends from dirt and damage.
53. Important: The weight of the engine should never be supported by the J 42203 .
Install the J 42203 to the close-out panel flange.
54. Slowly lower the vehicle onto the J 39580 and the J 39580-500 .
55. Support the engine and crossmember on the J 39580 and the J 39580-500 .
56. Using HAND TOOLS ONLY, remove the front and rear crossmember nuts.
57. Partially raise the vehicle.
58. Remove the AIR pipe bracket bolt at the rear of the cylinder head.
59. Remove the AIR pipe, with check valve, and the gasket.
60. Remove the ground strap bolt (5).
61. Remove the ground strap (6) from the left rear cylinder head.
62. Disconnect the following electrical connectors from the back of the engine:
^ The engine oil pressure sensor (2)
^ The manifold absolute pressure (MAP) sensor (3)
^ The camshaft position (CMP) sensor (4)
63. Disconnect the electrical connector for the knock sensor, left side.
64. Disconnect the electrical connector for the knock sensor, right side.
65. Disconnect the vacuum hose from the MAP sensor.
66. Remove the driveline support bolts.
67. Important: Visually inspect the transmission wiring harness to ensure detachment from the engine.
Insert a flat-bladed screwdriver, or similar tool, between the edge of the driveline support and the flywheel housing, then separate the flywheel housing from the driveline support.
68. Slowly pull the engine away from the propeller shaft.
69. As soon as the propeller input shaft clears the flywheel housing, slowly raise the vehicle.
70. Slide the engine and crossmember forward in order to clear the propeller shaft spline.
71. Important: Visually inspect the wiring harness clearances while raising the vehicle.
Raise the vehicle completely off of the engine and crossmember.
72. Remove the power steering pump pulley hub cap, if necessary.
73. Using the J 25034-C remove the power steering pump pulley.
74. Important: It is not necessary to open the power steering system during the engine removal procedure.
Remove the power steering pump bolts.
75. Remove the power steering pump brace.
76. Remove the power steering pump, with reservoir, from the engine, and reposition them to the crossmember.
77. Remove the power steering pump assembly.
78. Remove the generator bracket bolts.
79. Remove the generator bracket and power steering pump bracket.
80. Install the J 41798 to the engine.
81. Remove the spark plugs.
82. Remove the engine mount nuts.
83. Using a engine hoist and the J 41798 slowly raise the engine.
84. Remove the engine from the crossmember.
85. Remove the flywheel housing bolts.
86. Remove the flywheel housing from the engine block.
87. Install the engine onto an engine stand and prepare for disassembly.
88. Remove the engine hoist.
89. Remove the J 41798 from the engine.
80. Remove the engine mount bracket bolts.
81. Remove the engine mount brackets from the engine block.