Special Tools

1. Center the steering wheel.
2. Turn the ignition OFF.
3. Install J 42640 to the steering column.




Note: Do NOT disconnect the battery cables from the engine.

4. Disconnect the negative cable from the battery and the body. Refer to Battery Negative Cable Replacement.
5. Disconnect the positive cable from the battery and the underhood electrical center. Refer to Battery Positive Cable Replacement.
6. Position and secure the battery cables to the engine.
7. Remove the battery. Refer to Battery Replacement.
8. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.



9. Remove the air cleaner duct. Refer to Air Cleaner Inlet Duct Replacement.



10. Disconnect the cooling fan electrical connectors (2, 3).
11. Remove the cooling fan wiring harnesses (1, 4) from the fan shroud.
12. Secure the wiring harnesses to the vehicle.
13. Drain the cooling system. Refer to Cooling System Draining and Filling.

Note: Do NOT disconnect the surge hoses from the engine or the radiator.

14. Disconnect the surge tank outlet hose from the surge tank. Refer to Radiator Surge Tank Inlet Hose/Pipe Replacement.
15. Position and secure the surge hose to the engine.
16. Disconnect the surge tank inlet hose from the water outlet housing and the radiator. Refer to Radiator Surge Tank Outlet Hose/Pipe Replacement.
17. Position and secure the surge tank inlet hose to the vehicle.



18. Disconnect the purge line (3) from the purge solenoid.
19. Disconnect the fuel pipe (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service.
20. Plug the fuel pipe and cap the fuel rail to prevent fuel loss or contamination.
21. Evacuate the air conditioning system. Refer to Refrigerant Recovery and Recharging.
22. Remove the wiper module. Refer to Windshield Wiper System Module Replacement.

Note: Do NOT disconnect the suction hose from the A/C compressor.

23. Disconnect the air conditioning suction hose from the evaporator and remove the suction hose bracket from the shock tower. Refer to Suction Hose Replacement.
24. Position and secure the suction hose to the engine.

Note: Do NOT disconnect the liquid line from the condenser.

25. Disconnect the air conditioning pressure switch electrical connector and remove the liquid line. Refer to Liquid Line Replacement.
26. Remove the radiator support brackets. Refer to Radiator Support Bracket Replacement.



27. Disconnect the brake booster check valve and vacuum hose (1) from the brake booster (2).
28. Position and secure the brake booster hose to the engine.
29. Disconnect the electrical connector to the brake fluid level switch from the master cylinder.
30. Disconnect the electrical connector to the mass air flow sensor.
31. Unlock and disconnect the instrument panel (I/P) electrical connector from the engine located at the rear of the left bank 2 cylinder head.
32. Position and secure the I/P harness to the vehicle.



33. Disconnect the engine module wiring harness connectors (1-3) from the underhood electrical center. Refer to Underhood Electrical Center or Junction Block Replacement.
34. Disconnect the wiring harness from the transmission control module (TCM). Refer to Transmission Control Module Replacement.



35. Remove the ground bolt and wire from the longitudinal rail.



36. Unlock and disconnect the front engine wiring harness electrical connector from the engine control module (ECM).



37. Unlock and disconnect the rear engine wiring harness electrical connector from the ECM.



38. Disconnect the engine harness electrical connector at the longitudinal rail.
39. Position and secure the ground wire, the engine harness and the TCM harness to the engine.




Note: Do NOT disconnect the brake pipes from the master cylinder.

40. Remove the master cylinder nuts.
41. Reposition and secure the master cylinder to the engine.
42. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.
43. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
44. Remove the muffler assembly. Refer to Exhaust System Replacement.
45. Remove the propeller shaft. Refer to Rear Propeller Shaft Replacement.
46. Remove the air deflector. Refer to Front Air Deflector Replacement.

Note: DO NOT remove the water bottle.

47. Remove the washer bottle bracket. Refer to Headlamp Washer Solvent Container Replacement.
48. Disconnect the side air baffles from the radiator.
49. Disconnect the left front brake pipe retainer along with the brake pipe from the longitudinal rail.
50. Remove the right front brake pipe from the brake pipe bundle retainer.
51. Disconnect the rear brake pipes from the brake pressure modulator valve (BPMV). Refer to Brake Pressure Modulator Valve Replacement.
52. Plug the brake pipes and the brake modulator valve in order to minimize brake fluid loss.
53. Remove the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation.
54. Remove the lower intermediate steering shaft. Refer to Lower Intermediate Steering Shaft Replacement.



55. Remove the lower engine mount nuts. Refer to Engine Mount Replacement - Left Side and to Engine Mount Replacement - Right Side.



56. Disconnect the transmission shift linkage from the transmission. Refer to Shift Control Linkage Replacement.
57. Disconnect the electrical connector to the low oil level sensor.

Secure the electrical connector and the harness to the engine mount bracket.

58. Remove the headlamp leveling sensors. Refer to Headlamp Leveling Control Module Replacement.
59. Secure the shock modules to the lower control arms with a suitable strap in order to prevent damage to the front brake hoses.



60. Remove the upper mounting bolts from the right and left shock module. Refer to Shock Absorber and Spring Assembly Replacement.
61. Raise the vehicle enough to place a suitable lift table under the engine, transmission, front frame and front suspension assembly.
62. Position a suitable powertrain or engine lift table below the frame, engine and transmission.
63. Raise the lift table or lower the vehicle to support the frame, engine and transmission.
64. Remove the bolts which secure the transmission brace to the underbody. Refer to Transmission Support Replacement.



65. Remove the front frame bolts (2).

Note: Ensure that all the hoses, wires, pipes and shock modules clear the vehicle during the removal process.

66. With the aid of an assistant, lower the table or raise the vehicle to remove the engine, transmission, front frame and front suspension assembly from the vehicle.

Note: Do NOT remove the oxygen sensors.

67. Remove the catalytic converters with the oxygen sensors. Refer to Catalytic Converter Replacement - Left Side and to Catalytic Converter Replacement - Right Side.
68. Remove the thermostat housing with the heater pipes, heater hoses and surge tank outlet hose. Refer to Engine Coolant Thermostat Housing Removal.
69. Remove the starter motor. Refer to Starter Replacement.
70. Remove the flywheel bolts.



71. Remove the heated oxygen sensor (HO2S) connector bracket (1) from the left cylinder head.
72. Remove the engine wiring harness and related components. Refer to Engine Wiring Harness Assembly Removal.
73. Disconnect the transmission oil cooler pipes from the engine, radiator and the transmission.
74. Disconnect the radiator hoses from the water outlet housing and the coolant inlet pipe. Refer to Radiator Inlet Hose Replacement.
75. Disconnect the power steering cooler hoses from the condenser radiator and fan module (CRFM). Refer to Power Steering Cooler Pipe/Hose Replacement.
76. Plug the power steering hoses and pipes in order to prevent fluid loss and contamination.
77. Remove the CRFM with the radiator hoses from the frame.
78. Install EN 46114 to the engine. Refer to Engine Support Fixture.
79. Connect a floor crane to the engine lift brackets and raise the floor crane to partially support the engine.
80. Position a second powertrain lift table below the transmission.
81. Remove the bolts that secure the transmission to the engine. Refer to Transmission Replacement.
82. Remove the transmission from the engine.
83. Remove the drive belts. Refer to Water Pump and Generator Belt Replacement and to Air Conditioning Compressor and Power Steering Pump Belt Replacement.
84. Remove the generator and water pump drive belt tensioner. Refer to Drive Belt Tensioner Removal - Right Side.
85. Remove the A/C compressor and power steering drive belt tensioner. Refer to Drive Belt Tensioner Removal - Left Side.
86. Remove the generator and the generator bracket. Refer to Generator Removal.
87. Remove the A/C compressor. Refer to Air Conditioning (A/C) Compressor Removal.
88. Remove the power steering pump. Refer to Power Steering Pump Removal.
89. Remove the power steering reservoir from the engine. Refer to Power Steering Fluid Reservoir Replacement.
90. Remove the oil level indicator. Refer to Oil Level Indicator and Tube Removal.
91. Remove the left exhaust manifold. Refer to Exhaust Manifold Removal - Left Side.
92. Remove the oil filter adapter. Refer to Oil Filter Adapter Removal.
93. Remove the right exhaust manifold. Refer to Exhaust Manifold Removal - Right Side.
94. Remove the crankshaft balancer. Refer to Crankshaft Balancer Removal.
95. Remove the flywheel. Refer to Engine Flywheel Removal.
96. Remove the intake manifold. Refer to Intake Manifold Removal.
97. Remove the water outlet. Refer to Water Outlet Removal.
98. Remove the ECM with the ECM bracket. Refer to Engine Control Module Replacement.
99. Use a floor crane in order to remove the engine from the frame.
100. Remove the engine mount brackets with the engine mounts. Refer to Engine Mount Bracket Replacement - Left Side and to Engine Mount Bracket Replacement - Right Side.

1. Install the engine mount brackets with the engine mounts. Refer to Engine Mount Bracket Replacement - Left Side and to Engine Mount Bracket Replacement - Right Side.
2. Use a floor crane in order to install the engine to the frame.
3. Install the ECM with the ECM bracket. Refer to Engine Control Module Replacement.
4. Install the water outlet. Refer to Starter Installation.
5. Install the flywheel. Refer to Engine Flywheel Installation.
6. Install the intake manifold. Refer to Intake Manifold Installation.
7. Install the crankshaft balancer. Refer to Crankshaft Balancer Installation.
8. Install the right exhaust manifold. Refer to Exhaust Manifold Installation - Right Side.
9. Install the oil filter adapter. Refer to Oil Filter Adapter Installation.
10. Install the left exhaust manifold. Refer to Exhaust Manifold Installation - Left Side.
11. Install the oil level indicator. Refer to Oil Level Indicator and Tube Installation.
12. Install the generator and the generator bracket. Refer to Generator Installation.
13. Install the power steering pump. Refer to Power Steering Pump Installation.
14. Install the power steering reservoir to the engine. Refer to Power Steering Fluid Reservoir Replacement.
15. Install the A/C compressor. Refer to Air Conditioning (A/C) Compressor Installation.
16. Install the A/C compressor and power steering drive belt tensioner. Refer to Drive Belt Tensioner Installation - Left Side.
17. Install the generator and water pump drive belt tensioner. Refer to Drive Belt Tensioner Installation - Right Side.
18. Install the drive belts. Refer to Water Pump and Generator Belt Replacement and to Air Conditioning Compressor and Power Steering Pump Belt Replacement.
19. Install the bolts that secure the transmission to the engine and the flywheel to the torque convertor. Refer to Transmission Replacement.
20. Install the starter motor. Refer to Starter Replacement.
21. Remove EN 46114 from the engine. Refer to Engine Support Fixture.
22. Install the CRFM with the radiator hoses to the frame.
23. Connect the power steering cooler hoses to the CRFM. Refer to Power Steering Cooler Pipe/Hose Replacement.
24. Connect the radiator hoses to the water outlet housing and the coolant inlet pipe. Refer to Radiator Inlet Hose Replacement.
25. Install the transmission oil cooler pipes to the engine, radiator and the transmission.
26. Install the engine wiring harness and related components. Refer to Engine Wiring Harness Assembly Installation.



27. Install the HO2S connector bracket (1) to the left cylinder head.
28. Install the thermostat housing with the heater pipes, heater hoses and surge tank outlet hose. Refer to Engine Coolant Thermostat Housing Removal.
29. Install the catalytic converters with the oxygen sensors. Refer to Catalytic Converter Replacement - Left Side and to Catalytic Converter Replacement - Right Side.
30. Install the fuel lines to the fuel rail and the EVAP purge solenoid. Refer to Metal Collar Quick Connect Fitting Service.




Note: Ensure that all the hoses, wires, pipes and shock modules clear the vehicle during the installation process.

31. With the aid of an assistant, raise the table or lift the vehicle to install the engine, transmission, front frame and front suspension assembly to the vehicle.



32. Install the front frame bolts (2). Refer to Front Frame Replacement.
33. Install the transmission support to underbody bolts. Refer to Transmission Support Replacement.
34. Remove the powertrain lift/support table.



35. Install the upper mounting bolts to the right and left shock module. Refer to Shock Absorber and Spring Assembly Replacement.
36. Secure the shock modules to the front frame with mechanics wire to avoid stretching the front brake hoses.
37. Install the headlamp leveling sensors. Refer to Headlamp Leveling Control Module Replacement.



38. Connect the transmission shift linkage to the transmission. Refer to Shift Control Linkage Replacement.
39. Connect electrical connector to the low oil level sensor.



40. Install the lower engine mount nuts. Refer to Engine Mount Replacement - Left Side and to Engine Mount Replacement - Right Side.
41. Install the lower intermediate steering shaft. Refer to Lower Intermediate Steering Shaft Replacement.
42. Install the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation.
43. Install the front brake pipes and retainers to the underbody.
44. Connect the rear brake pipes to the BPMV. Refer to Brake Pressure Modulator Valve Replacement.
45. Connect the side air baffles to the radiator.
46. Install the washer bottle bracket. Refer to 139133 .
47. Install the air deflector. Refer to 9341 .
48. Install the propeller shaft. Refer to Rear Propeller Shaft Replacement.
49. Install the muffler assembly. Refer to Exhaust System Replacement.



50. Install the master cylinder. Refer to Master Cylinder Replacement.



51. Connect the engine harness electrical connector at the longitudinal rail.



52. Connect and lock the rear engine wiring harness electrical connector to the ECM.



53. Connect and lock the front engine wiring harness electrical connector to the ECM.

Caution: Refer to Fastener Caution in the Preface section.




54. Install the ground wire and bolt to the longitudinal rail.

Tighten
Tighten the bolt to 10 N·m (89 lb in).

55. Connect the wiring harness to the transmission control module. Refer to Transmission Control Module Replacement.



56. Connect the engine module wiring harness connectors (1-3) to the underhood electrical center. Refer to Underhood Electrical Center or Junction Block Replacement.
57. Connect and lock the I/P electrical connector to the engine at the rear of the left Bank 2 cylinder head.
58. Connect the mass air flow sensor electrical connector.
59. Connect the electrical connector for the brake fluid level switch from the master cylinder.



60. Connect the brake booster vacuum hose (1) to the brake booster (2).
61. Install the radiator support brackets. Refer to Radiator Support Bracket Replacement.



62. Connect the purge line (3) to the purge solenoid.
63. Connect the fuel pipe (2) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service.
64. Install the air inlet duct.
65. Position and secure the surge tank inlet hose to the vehicle.
66. Connect the surge tank inlet hose to the water outlet housing and to the radiator. Refer to Radiator Surge Tank Outlet Hose/Pipe Replacement.
67. Connect the outlet hose to the surge tank. Refer to Radiator Surge Tank Inlet Hose/Pipe Replacement.
68. Connect the electrical connector for the air conditioning pressure switch and the liquid line to the evaporator. Refer to Liquid Line Replacement.
69. Connect the air conditioning suction hose to the evaporator and install the suction hose bracket to the shock tower. Refer to Suction Hose Replacement.



70. Install the air cleaner duct. Refer to Air Cleaner Inlet Duct Replacement.



71. Install the cooling fan wiring harnesses (1, 4) to the fan shroud.
72. Install the cooling fan electrical connectors (2, 3).
73. Install the wiper module. Refer to Windshield Wiper System Module Replacement.
74. Install the battery. Refer to Battery Replacement.
75. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement.



76. Connect the positive cable to the battery and the underhood electrical center. Refer to Battery Positive Cable Replacement.
77. Connect the negative cable from the battery and the body. Refer to Battery Negative Cable Replacement.



78. Remove J 42640 from the steering column.
79. Fill the cooling system. Refer to Cooling System Draining and Filling.
80. Charge the air conditioning system. Refer to Refrigerant Recovery and Recharging.
81. Bleed the brake rear circuits. Refer to Hydraulic Brake System Bleeding.