Engine Replacement Preferred Method

Tools Required

Important: The preferred method of removing the engine assembly is through the bottom of the vehicle. If the necessary equipment is not available, use the alternate service removal procedure.

1. Disable the SIR. Refer to Supplemental Inflatable Restraint.
2. Recover the air-conditioning system. Refer to Heater Ventilation and Air Conditioning.
3. Remove the tower-to-tower brace.
4. Remove the air intake duct.
5. Remove the air cleaner assembly.
6. Remove the drain cooling system. Refer to Coolant Replacement in Engine Cooling.
7. Remove the radiator hose at the crossover.
8. Remove the engine cover.
9. Remove the radiator upper cover.
10. Remove the upper radiator hoses from the engine.
11. Remove the forward discriminating sensor from the radiator support and set it aside.
12. Remove the cooling fans. Refer to Cooling Fan Replacement in Engine Cooling.



13. Remove the transmission cooler lines from the radiator.
14. Remove the cruise control servo connections.
15. Remove the throttle and cruise control cables from the throttle body. Refer to Throttle Body Assembly Replacement
16. Remove the shift cable from the manual shift lever and the bracket.
17. Remove the vacuum hose from the brake booster.
18. Using J 37088-A disconnect the fuel inlet and return the lines.
19. Remove the coolant reservoir.
20. Remove the coolant hoses from the pipes at the front of the engine.
21. Remove the negative battery cable from the left cylinder head. Refer to

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

    in General Information.
22. Remove the positive battery cable from the battery and body retainer.
23. Remove the PCM case and the PCM.
24. Remove the right sound insulator.
25. Remove the engine wire harness electrical connector and the vacuum line under the instrument panel.
26. Remove the wire harness from the pass through at the cowl and pull the harness through the cowl.
27. Remove the three electrical connectors from the A/C line near the engine cowl.
28. Remove the vacuum hose from the "T" fitting near the engine harness pass through.
29. Remove the right and left front wheel speed sensor electrical connectors.
30. Remove the MAP sensor and the control motor near the master cylinder.
31. Remove the engine harness retainer from the brake booster.
32. Remove the two hoses from the power steering cooler.
33. Remove the engine harness from the hood fuse panel.
34. Remove the three relays from the lower radiator and the electrical connector from the ABS modulator.
35. Remove both tires and wheels.
36. Separate the drive axles from the steering knuckle. Refer to Drive Axle On-Vehicle Service.
37. Remove the post oxygen sensor heat shield.
38. Remove the post oxygen sensor wire harness connector from the body.
39. Remove the intermediate pipe hangers form the intermediate pipe. Refer to Engine Exhaust.
40. Remove the catalytic converter from the pipe. Refer to Engine Exhaust.
41. Remove the steering coupling from the steering gear. Refer to Steering Wheel and Column.
42. Remove the fuel line bundle from the transmission.
43. Remove the battery wire from the generator.
44. Remove the A/C manifold from the A/C compressor. Refer to Heater Ventilation and Air Conditioning.
45. Remove the ABS modulator from the frame and support.
46. Position the powertrain support table J 39580 under the frame and lower the vehicle onto the table.
47. Remove the six frame to body bolts.
48. Raise the body off the powertrain.
49. Remove the coolant crossover pipe from the engine.
50. Remove the Park/Neutral switch from the transmission.
51. Remove the engine wire harness.
52. Remove the exhaust "Y" pipe. Refer to Engine Exhaust.
53. Remove the accessory drive belt. Refer to Drive Belt Replacement .
54. Remove the power steering pump and hoses. Refer to Power Steering Gear and Pump.
55. Remove the generator and the bracket. Refer to Generator Replacement in Engine Electrical.
56. Remove the A/C compressor and the bracket. Refer to Heater Ventilation and Air Conditioning.
57. Remove the idler pulley.



58. Remove the right engine to transmission brace.



59. Remove the lower engine to the transmission brace.
60. Remove the left engine to the transmission brace.
61. Attach the engine lift to the engine.
62. Remove the left engine mount and bracket.
63. Remove the left exhaust manifold. Refer to Exhaust Manifold Replacement .
64. Remove the flywheel inspection cover.
65. Remove the torque converter from the flywheel.
66. Remove the right engine mount bracket from the engine.



67. Remove the transmission (bell housing) to engine bolts.
68. Remove the engine from the transmission and frame assembly.
69. Remove the cross under pipe, EGR.
70. Remove the right exhaust manifold. Refer to Exhaust Manifold Replacement

1. Install the right exhaust manifold. Refer to Exhaust Manifold Replacement .
2. Install the cross under pipe, EGR.
3. Install the engine to transmission and frame assembly.



4. Install four transmission (bell housing) to engine bolts.

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

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.

5. Install the right engine mount bracket to the engine.
6. Install the torque converter to the flywheel.

Tighten
Tighten the bolts to 47 N·m (35 lb ft).

7. Install the flywheel inspection cover.
8. Install the left exhaust manifold. Refer to Exhaust Manifold Replacement .
9. Install the left engine mount and bracket.
10. Disconnect the engine lift from the engine.
11. Install the left engine to the transmission brace.
12. Lower the engine to the transmission brace.



13. Install the right side engine to the transmission brace.
14. Install the right side coolant pipes to the engine.
15. Install the power steering lines to the pump and the pump to the engine. Refer to Power Steering Gear and Pump.
16. Install the idler pulley.

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

17. Install the A/C compressor and the brackets to the engine. Refer to Heater Ventilation and Air Conditioning.
18. Install the generator and bracket to the engine. Refer to Generator Replacement in Engine Electrical.
19. Install the power steering pump pulley. Refer to Power Steering Gear and Pump.
20. Install the accessory drive belt. Refer to Drive Belt Replacement .
21. Install the exhaust manifold rear pipe.
22. Install the engine wire harness.
23. Install the Park/Neutral switch and bracket to the transmission. Refer to Automatic Transmission General Information for adjustment.
24. Install the coolant crossover pipe.
25. Position the powertrain assembly under the body.
26. Lower the body onto the powertrain assembly.
27. Install the frame to body bolts.

Tighten
Tighten the bolts to 100 N·m (74 lb ft).

28. Install the ABS modulator to the frame.
29. Install the A/C manifold to the A/C compressor. Refer to Heater, Ventilation, and Air Conditioning..
30. Install the battery wire to the generator.
31. Install the fuel line bundle to the transmission.
32. Install the steering coupling to the steering gear. Refer to Steering Wheel and Column.
33. Install the catalytic converter to the front pipe. Refer to Engine Exhaust.
34. Install the intermediate pipe hangers to the intermediate pipe.
35. Install the post converter oxygen sensor electrical connection.
36. Install the post converter oxygen sensor heat shield.
37. Install the drive axle to the hubs. Refer to Drive Axle On-Vehicle Service.
38. Install the tie rods.
39. Install the height sensor links.
40. Install the stabilizer shaft links. Refer to Front Suspension.
41. Install the tire and the wheels.

Tighten
Tighten the wheel nuts to 140 N·m (100 lb ft).

42. Lower the vehicle.
43. Install three relays to the radiator support.
44. Install two hoses to the power steering cooler.
45. Install the engine harness to under the hood fuse panel.
46. Install the engine harness retainer to the brake booster.
47. Install the engine harness left front wheel speed sensor, cruise control motor and MAP sensor electrical connector near the master cylinder.
48. Install the right front wheel speed sensor electrical connector.
49. Install the vacuum hose to the "T" fitting near the engine harness pass through.
50. Connect the three electrical connections to the A/C line near the cowl.
51. Push the engine wire harness through the cowl and attach pass through to the cowl.
52. Connect the two engine wire harness electrical connection and vacuum line under the I/P.
53. Install the right sound insulator.
54. Install the PCM case, the PCM and the electrical connection.
55. Connect the positive battery cable to the battery and body retainer.
56. Connect the negative battery cable to the left cylinder head.
57. Install the coolant hoses to the pipes at the front of the engine.
58. Install the coolant reservoir, hoses and electrical connector.
59. Install the fuel lines to the fuel rail.
60. Install the vacuum hose to the brake booster.
61. install the shift cable to the manual shift lever and bracket.
62. Install the throttle and cruise cables to the throttle body.
63. Install the cooling fans. Refer to Engine Cooling.



64. Connect the transmission cooler lines to the radiator.
65. Install the forward discriminating sensor to the radiator support.
66. Install the upper and lower radiator hoses.
67. Install the engine mount struts and adjust to zero preload. Refer to Engine Mount Strut Replacement .
68. Install the radiator upper cover.
69. Install the engine cover.
70. Install the air cleaner assembly.
71. Install the air intake duct.
72. Install the fill cooling system. Refer to Engine Cooling.
73. Recharge the A/C system. Refer to Heater, Ventilation, and Air Conditioning..
74. Enable the SIR. Refer to Supplemental Inflatable Retraints.
75. Bleed the power steering system. Refer to Power Steering Gear and Pump.

Engine Replacement Alternate Method

Tools Required

1. Disable the SIR. Refer to Supplemental Inflatable Restraint.
2. Recover the air conditioning system. Refer to Heater Ventilation and Air Conditioning.
3. Remove the air cleaner and intake duct.
4. Remove the drain cooling system. Refer to Engine Cooling..
5. Remove the engine cover.
6. Remove the hood. Refer to Body Front End.
7. Remove the cross tower brace.
8. Remove the radiator upper cover.
9. Remove the left and right engine mount struts. Reinstall the bolt in the left front engine mount strut bracket as this will be used as an engine lift point. Refer to Engine Mount Strut Replacement .
10. Remove the upper and lower radiator hoses.
11. Disconnect the forward discriminating sensor from the radiator support and set it aside.
12. Remove the cooling fans. Refer to Engine Cooling.
13. Remove the transmission cooler lines from the radiator.
14. Remove the radiator upper mounting panel.
15. Disconnect the A/C condenser from the radiator.
16. Remove the radiator.
17. Remove the throttle and cruise control cables from the throttle body.
18. Remove the brake booster vacuum hose from the intake manifold.
19. Using J 37088-A disconnect the fuel inlet and return lines.
20. Remove the coolant reservoir.
21. Remove the A/C line between the accumulator and the evaporator. Refer to Heater Ventilation and Air Conditioning.
22. Disconnect the coolant hoses from the pipes at the front of the engine.
23. Remove the accessory drive belt. Refer to Drive Belt Replacement .
24. Remove the negative battery cable from the left cylinder head. Refer to

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

    in General Information.
25. Remove the positive battery cable from the battery and the body retainer. Refer to

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

    in General Information.
26. Remove the shift cable from the shift lever and the bracket.
27. Remove the Park/Neutral switch and bracket.
28. Remove the transmission vent hose and the shift cable from the throttle body bracket.
29. Remove the TP Sensor, the MAF sensor, Knock sensor and IAC valve connector.
30. Remove the ignition coil and the spark plug wires.
31. Remove the throttle body coolant hose at the water cross over.
32. Remove the EGR pipe and the crankcase vent pipe from the throttle body.
33. Remove the fuel rail ground wire from the right cylinder head and disconnect the fuel rail bracket from the EGR valve.
34. Remove the PCV valve from the right cam tower.
35. Disconnect the injector harness main electrical connector.
36. Remove the intake manifold. Refer to Intake Manifold Replacement .
37. Remove the starter. Refer to Starter Motor Replacement in Engine Electrical.
38. Remove the cylinder head temperature switch electrical connector and ground wire from the right cylinder head.
39. Raise and suitably support the vehicle. Refer to General Information.



40. Remove the transmission to oil pan brace.
41. Remove the left transmission to engine brace.
42. Remove the front engine splash shield and the flywheel inspection cover.
43. Remove the torque converter from the flywheel.
44. Disconnect the A/C compressor, generator, crank sensor, left oxygen sensor, oil level sensor and oil pressure sensor electrical connectors and disconnect the harness from the engine.
45. Remove the right engine splash shield.
46. Remove the A/C compressor and set aside. Refer to Heater Ventilation and Air Conditioning.
47. Remove the left motor mount to cradle.
48. Remove the post converter oxygen sensor heat shield.
49. Remove the pre-converter oxygen sensor electrical connector.
50. Remove the intermediate pipe hangers and the catalytic converter from the "Y" pipe.
51. Remove the right front engine to transmission brace.
52. Remove the transmission to cylinder head support from the transmission.
53. Remove the ground wire from the right side of the engine.
54. Remove the power steering pressure line retainer from the front of the engine.
55. Remove the left rear transmission to engine brace from the transmission.
56. Lower the vehicle.
57. Remove the left rear transmission to the engine brace.
58. Disconnect the engine harness from the right cam cover and set it aside.
59. Disconnect the vacuum line connector near the engine harness pass through.
60. Remove the power steering pump pressure and return lines from the pump. Refer to Power Steering Gear and Pump.
61. Remove the coolant cross over pipe.



62. Remove the four transmission to engine (bell housing) bolts.
63. Connect an engine lifting fixture to the engine using support hooks at the left rear and the right rear of the engine. Use the torque strut bracket at the left front of the engine for the third lift point. A load tilting device such as J 39456 will provide an extra degree of adjustment.
64. Remove the engine from the vehicle.

1. Lower the engine into position into the chassis. Use caution when moving the engine to prevent damage.



2. Install four engine to transmission (bell housing) bolts.

Tighten
Tighten the bolts to 100 N·m (74 lb ft).

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.

3. Remove the lifting fixture from the engine.
4. Install the coolant cross over pipe.
5. Install the power steering pump pressure and return the lines to the pump. Refer to Power Steering Gear and Pump.
6. Install the vacuum line connection near the engine harness pass through.
7. Install the engine harness to the right cam tower and the six electrical connections.
8. Install the left rear transmission to the engine brace.
9. Raise the vehicle and suitably support the vehicle. Refer to General Information..
10. Install the left rear transmission to engine brace to the transmission.
11. Install the power steering pressure line retainer to the front of the engine.
12. Connect the ground wire to the right side of the engine and bolt attaching the transmission to the cylinder head brace.
13. Install the transmission to cylinder head support to the transmission.



14. Install the right front engine to the transmission brace.
15. Install the catalytic converter to the exhaust manifold rear pipe. Refer to Engine Exhaust.
16. Install the intermediate pipe hangers. Refer to Engine Exhaust.
17. Install the electrical connection at the pre-converter oxygen sensor and heat shield.
18. Install two nuts attaching the left motor mount to the cradle.
19. Install the A/C compressor to the engine. Refer to Heater Ventilation and Air Conditioning.
20. Install the right engine splash shield.
21. Connect the A/C compressor, Generator, Crank Sensor, Oxygen Sensor, Oil Level Sensor, and Oil Pressure Sensor Electrical connectors.
22. Install the torque converter to the flywheel.

Tighten
Tighten the torque converter to 47 N·m (35 lb ft).

23. Install the flywheel inspection cover.
24. Install the front engine splash shield.
25. Install the left transmission to the engine brace.



26. Install the transmission to the oil pan brace.

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

27. Lower the vehicle
28. Install the ignition coil pack and the spark plug wires.
29. Connect the cylinder head temperature switch electrical connector and ground wire to the rear of the right cylinder head.
30. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.
31. Install the intake manifold. Refer to Intake Manifold Replacement .
32. Connect the injector harness main electrical connector.
33. Install the PCV valve to the right cam cover.
34. Install the fuel rail bracket to the EGR valve.
35. Install the fuel rail ground wire to the right cylinder head.
36. Install the EGR pipe and the crankcase vent pipe to the throttle body.
37. Install the throttle body coolant hose at the water crossover.
38. Connect the TP Sensor, the MAF Sensor, and the IAC Valve electrical connectors.
39. Install the transmission vent hose and shift cable to the throttle body bracket.
40. Install the Park/Neutral switch and bracket. Refer to Automatic Transmission General Information.
41. Install the shift cable to the shift lever and bracket.
42. Connect the positive battery cable to the battery and the body retainer.
43. Connect the negative battery cable to the left cylinder head.
44. Install the accessory drive belt. Drive Belt Replacement .
45. Install the coolant hoses to the pipes at the front of the engine.
46. Install the coolant reservoir.
47. Install the A/C line between the accumulator and the evacuator core.
48. Install the fuel lines to the fuel rail.
49. Install the brake booster vacuum hose to the intake manifold.
50. Install the throttle and cruise control cables to the throttle body.
51. Install the radiator.
52. Install the A/C condenser to the radiator.
53. Install the cooling fans. Refer to Engine Cooling.



54. Install the transmission cooler lines.
55. Install the forward discriminating sensor to the radiator support.
56. Install upper and lower radiator hoses.
57. Install the right and left engine mount struts and adjust to zero preload as described in Engine Mount Strut Replacement .
58. Install the radiator upper cover.
59. Install the cross tower brace.
60. Install the hood. Refer to Body Front End.
61. Install the engine top cover. Refer to Engine Front Cover Replacement .
62. Install the air cleaner assembly.
63. Install the air intake duct and the air cleaner.
64. Install the refill cooling system. Refer to Engine Cooling.
65. Recharge the A/C system. Refer to Heater Ventilation and Air Conditioning.
66. Enable the SIR. Refer to Supplemental Inflatable Restraint.
67. Bleed the power steering system. Refer to Power Steering Gear and Pump.