Tools Required

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Recover the A/C Refrigerant System. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.
3. Remove the upper filler panel. Refer to Filler Panel Replacement - Upper in Body Front End.
4. Disconnect the connectors from the PCM. Refer to Powertrain Control Module Replacement/Programming in Engine Controls-4.6 L.
5. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls-4.6 L.
6. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
7. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .



8. Remove the two nuts (2) from the intake manifold sight shield (1).
9. Remove the sight shield (1) from the engine.



10. Position the J 37097-A to the clamp in order to remove the inlet radiator hose (1) from the engine.
11. Position the J 38185 to the clamp in order to remove the outlet radiator hose (2) from the thermostat housing.



12. Remove the upper transaxle oil cooler line retaining bolt from the fan shroud.
13. Slide the plastic cap off the upper transaxle oil cooler line quick connect fitting.
14. Remove the internal spring clip from the transaxle oil cooler fitting.
15. Remove the upper transaxle oil cooler line from the radiator.
16. Disconnect the lower transaxle oil cooler line from the radiator.



17. Disconnect the surge tank inlet hose (1) from the engine.
18. Disconnect the surge tank outlet hose (3) from the heater pipe.

Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.

In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.
19. Remove the accelerator control cable from the throttle body. Refer to Accelerator Control Cable Replacement in Engine Controls-4.6 L.
20. Disconnect the cruise control cable from the throttle body. Refer to Cruise Control Cable Replacement in Cruise Control.



21. Disconnect the heater hoses (1,2) from the engine.
22. Disconnect the two brake pipes from the master cylinder.

Plug the open outlet ports to prevent fluid loss and contamination.




23. Remove the bracket and shift cable (1) from the manual shift lever (2) and position aside.
24. Disconnect the vacuum hose from the brake booster.
25. Disconnect the EVAP hose from the EVAP purge valve.
26. Disconnect the fuel inlet and return quick-connect fittings at the fuel rail. Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service in Engine Controls-4.6 L and position aside.



27. Disconnect the engine ground cable (2) from the body frame rail.
28. Disconnect the main engine harness.
29. Disconnect the electrical harness from the underhood fuse block. Refer to Underhood Fuse Block Replacement in Engine Electrical.



30. Remove the right and left strut tower bolts.
31. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
32. Remove the right and left wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.



33. Disconnect the real time dampening sensor links (1) from the lower control arms.
34. Disconnect the right and left wheel speed sensor connectors.
35. Disconnect the right and left road sensing suspension electrical connectors.
36. Disconnect the two brake pipes from both front frame brackets.
37. Disconnect the two rear brake pipes at the rear of the engine frame.
38. Remove the air deflector. Refer to Front Air Deflector Replacement in Body Front End.




Important: Engine oil cooler quick connect fittings must be replaced whenever they are removed from the engine oil filter adapter.

39. Remove the engine oil cooler quick connect fittings from the engine oil filter adapter, with the oil lines still attached, and position aside.
40. Remove the dust cover from the quick connect joint.



41. Remove the internal spring clip from the engine oil cooler fittings.



42. Remove the engine oil cooler lines from the cooler fittings.



43. Disconnect the A/C discharge hose from the compressor.



44. Disconnect the A/C suction hose from the compressor.

Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the coil assembly in the steering column to become uncentered which will cause damage to the coil assembly.

45. Lock the steering column by removing the ignition key from the lock cylinder.



46. Remove the intermediate shaft pinch bolt.
47. Disconnect the steering gear from the intermediate shaft.
48. Disconnect the wheel speed and brake wear sensors at the right and left strut towers.
49. Disconnect the post HO2S at the sensor pigtail.
50. Remove the exhaust front pipe. Refer to Front Pipe Replacement in Engine Exhaust.



51. Remove the brace between the engine oil pan and the transaxle case.
52. Remove the torque converter cover. Refer to Torque Converter Cover Replacement in Automatic Transaxle-4T80-E.

Important: Mark the flywheel to torque converter relationship prior to removal of the bolts.

53. Remove the torque converter to the flywheel bolts.
54. Lower the vehicle.



55. Position the J 39580 powertrain support dolly under the engine assembly.



56. If the powertrain support dolly is unavailable. Support the powertrain with four suitable jackstands.



57. Remove the nut securing the right engine mount to the engine mount bracket.



58. Remove the nut (1) securing the left transaxle mount to the transaxle mount bracket.

Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

59. Secure the front hoist pads to the vehicle.



60. Remove the six frame mount bolts (3).
61. Raise the vehicle slowly.
62. Attach an engine lift to the engine.
63. Remove the heater pipes. Refer to Heater Inlet Pipe Replacement and Heater Outlet Pipe Replacement in Heating, Ventilation and Air Conditioning.



64. Remove the nut (3) securing the coil cassette ground wire to the cylinder head.
65. Disconnect the engine wiring harness from the engine. Refer to Engine Controls Component Views in Engine Controls-4.6L.
66. Remove the bolt securing the crossover pipe to the cylinder head.
67. Remove the power steering pump. Refer to Power Steering Pump Replacement in Power Steering System.



68. Remove the bolt (2) securing the rear transaxle brace (1) to the transaxle.
69. Remove the nuts (3) securing the rear transaxle brace (1) to the cylinder head.
70. Remove the rear transaxle brace.



71. Remove the bolt (1) securing the front transaxle brace (2) to the cylinder head.
72. Loosen the bolts (3) attaching the transaxle brace (2) to the transaxle.



73. Remove the bolts securing the transaxle brace to the engine.



74. Remove the nut securing the front engine mount to the engine frame.



75. Remove the bolts attaching the engine to the transaxle.
76. Raise the engine from the frame and transaxle assembly.

1. Position the engine to the frame and transaxle assembly.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the bolts attaching the engine to the transaxle.

Tighten
Tighten the bolts to 75 N·m (55 lb ft).




3. Install the nut securing the front engine mount to the engine frame.

Tighten
Tighten the nut to 70 N·m (52 lb ft).




4. Loosely install the four bolts securing the transaxle brace to the engine.

Tighten
Tighten the bolts to 50 N·m (37 lb ft).




5. Install the bolt (1) securing the front transaxle brace (2) to the cylinder head.

Tighten
Tighten the front transaxle brace bolts (1,3) to 50 N·m (37 lb ft).




6. Position the rear transaxle brace over the studs located at the rear of the right cylinder head.
7. Loosely install the nuts (3) securing the rear transaxle brace (1) to the cylinder head.
8. Install the bolt (2) securing the rear transaxle brace (1) to the transaxle.

Tighten

•	Tighten the rear transaxle brace bolt (2) to 50 N·m (37 lb ft).

•	Tighten the rear transaxle brace nuts (3) to 50 N·m (37 lb ft).




9. Install the bolt securing the crossover pipe to the cylinder head.

Tighten
Tighten the bolt to 25 N·m (18 lb ft).

10. Connect the engine wiring harness to the engine. Refer to Engine Controls Component Views in Engine Controls-4.6L.
11. Install the nut (3) securing the coil cassette ground wire to the cylinder head.

Tighten
Tighten the nut to 17 N·m (13 lb ft).

12. Install the heater pipes. Refer to Heater Inlet Pipe Replacement and Heater Outlet Pipe Replacement in Heating, Ventilation and Air Conditioning.
13. Install the power steering pump. Refer to Power Steering Pump Replacement in Power Steering System.



14. Remove the engine lift from the engine.
15. Position the engine/transaxle assembly under the vehicle.
16. Carefully lower the vehicle over the engine/transaxle assembly.

Using dowel pins in the alignment holes (1), align the engine frame (2) with the vehicle.

17. Install the six frame mounting bolts (3) retaining the frame (2) to the vehicle.

Tighten
Tighten the frame mounting bolts to 191 N·m (141 lb ft).




18. Install the nut (1) securing the left transaxle mount to the transaxle mount bracket.

Tighten
Tighten the nut to 80 N·m (59 lb ft).




19. Install the nut securing the right engine mount to the engine mount bracket.

Tighten
Tighten the nut to 80 N·m (59 lb ft).




20. Remove the J 39580 powertrain support dolly from under the engine assembly.
21. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.




Important: Line up the flywheel and converter, using the alignment marks made during disassemble.

22. Install the torque converter to flywheel bolts.

Tighten
Tighten the bolts to 60 N·m (44 lb ft).

23. Install the torque converter cover. Refer to Torque Converter Cover Replacement in Automatic Transaxle-4T80-E.
24. Install the oil pan to transaxle brace.

Tighten
Tighten the bolts to 50 N·m (37 lb ft).

25. Install the exhaust front pipe. Refer to Front Pipe Replacement in Engine Exhaust.
26. Connect the post HO2S at the sensor pigtail.
27. Connect the wheel speed and brake wear sensors at the right and left strut towers.



28. Connect the intermediate shaft to the steering gear.
29. Install the pinch bolt.

Tighten
Tighten the pinch bolt to 45 N·m (33 lb ft).




30. Connect the A/C suction hose to the compressor.

Tighten
Tighten the suction hose nut to 20 N·m (15 lb ft).




31. Connect the A/C discharge hose to the compressor.

Tighten
Tighten the discharge hose nut to 20 N·m (15 lb ft).





Important: Engine oil cooler quick connect fittings must be replaced whenever they are removed from the engine oil filter adapter.

32. Install the engine oil cooler quick connect fittings to the engine oil filter adapter.

Tighten
Tighten the quick connect fittings to 18 N·m (13 lb ft).




33. Push the engine oil cooler lines fully into the oil cooler quick connect fittings, until a "click" is heard.
34. Tug gently on the cooler lines to ensure proper retention.
35. Slide the dust cover over the quick connect joint.
36. Install the air deflector. Refer to Front Air Deflector Replacement in Body Front End.



37. Connect the real time dampening sensor links (1) to the lower control arms.
38. Connect the right and left road sensing suspension electrical connectors.
39. Connect the right and left wheel speed sensor connectors.
40. Connect the two brake pipes to both front frame brackets.

Tighten
Tighten the brake pipes to 15 N·m (11 lb ft).

41. Connect the two rear brake pipes at the rear of the engine frame.

Tighten
Tighten the brake pipes to 15 N·m (11 lb ft).




42. Position the right and left struts to the strut towers.
43. Install the right and left wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
44. Lower the vehicle.
45. Install the right and left strut tower bolts and washers.

Tighten
Tighten the strut tower bolts to 40 N·m (30 lb ft).




46. Connect the engine ground cable (2) to the body frame rail.
47. Connect the main engine harness.
48. Connect the electrical harness to the underhood fuse block. Refer to Underhood Fuse Block Replacement in Engine Electrical.



49. Install the shift cable (1) to the manual shift lever (2) and the bracket.
50. Connect the vacuum hose to the brake booster.
51. Connect the EVAP hose to the EVAP purge valve.
52. Connect the fuel inlet and return quick-connect fittings at the fuel rail. Refer to Metal Collar Quick Connect Fitting Service or Plastic Collar Quick Connect Fitting Service in Engine Controls-4.6 L.



53. Connect the heater hoses (1,2) to the engine.
54. Connect the two brake pipes to the master cylinder.

Tighten
Tighten the brake pipes to 15 N·m (11 lb ft).




55. Connect the surge tank inlet hose (1) to the engine.
56. Connect the surge tank outlet hose (3) to the heater pipe.

Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.

In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.
57. Install a NEW accelerator control cable to the throttle body. Refer to Accelerator Control Cable Replacement in Engine Controls-4.6 L.
58. Connect the cruise control cable to the throttle body. Refer to Cruise Control Cable Replacement in Cruise Control.



59. Connect the lower transaxle oil cooler line to the radiator.

Important: Ensure the transaxle oil cooler line is positioned upwards while tightening.

Tighten
Tighten the transaxle oil cooler line to 35 N·m (26 lb ft).




60. Secure the spring clip to the fitting.
61. Push the upper transaxle oil cooler line into the radiator quick connect fitting, until a "click" is heard.
62. Tug gently on the cooler line to ensure proper retention.
63. Slide the plastic cap (1) over the quick connect joint.



64. Install the upper transaxle oil cooler line retaining bolt to the fan shroud.

Tighten
Tighten the transaxle oil cooler line retaining bolt to 6 N·m (53 lb in).




65. Position the J 38185 to the clamp in order to connect the outlet radiator hose (2) to the thermostat housing.
66. Position the J 37097-A to the clamp in order to connect the inlet radiator hose (1) to the engine.



67. Position the intake manifold sight shield (1) to the engine.
68. Install the two intake manifold sight shield nuts (2).

Tighten
Tighten the nuts to 3 N·m (27 lb in).

69. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
70. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls-4.6 L.
71. Connect the connectors to the PCM. Refer to Powertrain Control Module Replacement/Programming in Engine Controls-4.6 L.
72. Install the upper filler panel. Refer to Filler Panel Replacement - Upper in Body Front End.
73. Recharge the A/C Refrigerant System. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.
74. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
75. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement .
76. Operate and test the engine. Refer to Engine Set-Up and Testing .
77. Perform the CKP system Variation learn procedure. Refer to Crankshaft Position System Variation Learn in Engine Controls-4.6 L.
78. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.
79. Measure the wheel alignment. Refer to Wheel Alignment Measurement in Wheel Alignment.