Notice

The steps in the following procedure are in a specific order. Follow these steps in this order and ignore no details or vehicle damage could occur.

Tools Required

1. Disconnect the negative battery cable. 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.
2. Evacuate the A/C system. Refer to Evacuation in HVAC.
3. Raise the vehicle and support. Refer to Lifting and Jacking the Vehicle in General Information.
4. Drain the coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
5. Lower the vehicle.



6. Disconnect the IAT sensor connector.
7. Disconnect the MAF sensor connector.



8. Disconnect the fuel regulator purge line from the air intake duct.
9. Remove the air intake duct and the air cleaner assembly.



10. Remove the accessory drive belt. (5)



11. Remove the fuel rail covers.
12. Relieve the fuel system pressure using J 34730-1A .

Important: Cap the fittings and plug the holes when separating fuel system components in order to prevent dripping of fuel and/or dirt and other contaminants from entering the fuel system.




13. Disconnect the fuel lines (3 and 4) at the fuel rail.



14. Disconnect the radiator hoses from the water pump.



15. Disconnect the heater hoses from the water pump.



16. Disconnect the following electrical connectors:

16.1.

Fuel injectors

16.2.

Ignition coil main connectors

16.3.

EVAP solenoid

16.4.

Electric throttle motor

16.5.

Throttle position sensor

16.6.

ECT sensor

16.7.

A/C compressor




17. Disconnect the generator electrical connectors.



18. Remove the generator rear bracket bolts.
19. Remove the generator rear bracket.



20. Remove the generator mounting bolts.
21. Remove the generator.



22. Disconnect the brake booster vacuum hose from the brake booster.



23. Remove the intermediate shaft to steering gear bolt.
24. Disconnect the intermediate steering shaft from the steering gear and slave left to the frame rail.



25. Disconnect the AIR hose from the LH exhaust manifold.

Important: Do not remove the engine flywheel housing to driveline support assembly bolts until it is called out in the procedure.

26. Raise the vehicle.
27. Remove the front tire and wheel assemblies.
28. Remove the intermediate exhaust pipe. Refer to Intermediate Pipe in Engine Exhaust.



29. Remove the close-out panel bolts.
30. Remove the close-out panel.



31. Remove the starter electrical connectors.
32. Remove all grounds from the right side of the engine block.



33. Remove the starter bolts.
34. Remove the starter.



35. Disconnect the oil level sensor connector.
36. Disconnect the crank position sensor connector.
37. Disconnect the RH front HO2S connector.



38. Remove the A/C compressor hose retaining bolt.
39. Remove the A/C compressor hose from the A/C compressor.



40. Disconnect the engine oil temperature sensor connector.
41. Disconnect all grounds from the left side of the engine block.
42. Disconnect the LH front HO2S connector.



43. Remove the front stabilizer bar bolts and straps.
44. Disconnect the front stabilizer bar from the cradle.



45. Disconnect the electrical connectors and harness from the electric cooling fans.



46. Remove the electric cooling fan bolts.
47. Remove both electric cooling fans.



48. Install J 33432-A to the front spring.
49. Compress the front transverse spring using J 33432-A .



50. Remove the tie rod end nuts. (3)
51. Remove the tie rod ends (5) from steering knuckles (4) using J 42188 .
52. Disconnect the ABS electrical connectors at the cradle.
53. Disconnect the EVO connector at the cradle.
54. Disconnect the RTD connectors at the cradle. (if equipped)



55. Remove the lower shock absorber mounting bolts.



56. Separate the lower ball joints using J 42188 .



57. Remove J 33432-A from the front spring.



58. Disconnect the automatic transmission cooler lines at the engine flywheel housing junction. (if equipped)



59. Disconnect the automatic transmission cooler lines from the radiator. (if equipped)



60. With automatic transmission vehicles, use the following steps:

60.1.

Remove the two plugs in the driveline support assembly.

Important: Failure to use the minimum fastener length specified will prevent proper retention of the propeller shaft during disassembly.

60.2.

Install a M10.0 X 1.5 bolt, 55 millimeters or longer in each location.

Tighten
Tighten the M10.0 bearing support bolts to 35 N·m (26 lb ft).




61. With automatic transmission vehicles, remove the engine flywheel housing access plug.



62. Orientate the automatic transmission flywheel hub collar to access the bolt (1).
63. Loosen the automatic transmission flywheel hub collar bolt (1).




Important: The weight of the engine should never be supported by J42203.

64. Install J 42203 to the close-out panel flange.
65. Partially lower the vehicle.
66. Support the engine and front cradle assembly on J 39580 .
67. Remove the front cradle nuts.
68. Partially lower the engine and front cradle.



69. Disconnect the following electrical connectors:

69.1.

Engine oil pressure gauge

69.2.

Camshaft position sensor

69.3.

MAP sensor

69.4.

Knock sensor

69.5.

ground on rear of LH head

69.6.

All remaining electrical connections




70. Remove the front driveline support assembly bolts.
71. Slide the engine and cradle assembly forward to clear the propeller shaft spline.
72. Raise the vehicle completely off of the engine and cradle assembly.

Important: It is not necessary to open the P/S system during the engine removal procedure.

73. Remove the P/S pump and reservoir from the engine and slave to the cradle.



74. Remove the engine mount to cradle nuts.
75. Remove the engine from the cradle.

Notice

The steps in the following procedure are in a specific order. Follow these steps in this order and ignore no details or vehicle damage could occur.

1. Install the engine to the front cradle.
2. Install the engine mount to cradle nuts.

Tighten
Tighten the engine mount nuts to 54 N·m (40 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. Install the P/S pump and reservoir to the engine.

Tighten
Tighten the P/S pump mounting bolts to 25 N·m (18 lb ft).

4. Partially lower the vehicle to the engine and front cradle assembly.



5. Route the electrical harnesses and connect the following electrical connectors:

5.1.	Engine oil pressure gauge

5.2.	Camshaft position sensor

5.3.	MAP sensor

5.4.	Knock sensor

5.5.	Ground on rear of LH head

5.6.	All remaining electrical connections at the rear of the engine





Important: Do not tighten the flywheel hub collar bolt at this time.

6. Slide the engine and front cradle assembly rearward and install the propeller shaft spline to the engine. Do not force the engine onto the propeller spline.
7. Install the front driveline support bolts.

Tighten
Tighten the engine flywheel housing to driveline support assembly bolts to 50 N·m (37 lb ft).

8. Lower the vehicle on to the cradle and align dowels.
9. Install the front cradle nuts.

Tighten
Tighten the front cradle nuts to 110 N·m (81 lb ft).

10. Raise the vehicle.



11. Remove J 42203 from the vehicle.



12. Install J 33432-A to the front spring.
13. Compress the front transverse spring using J 33432-A .



14. Install the lower shock absorber mounting bolts.

Tighten
Tighten the shock absorber mounting bolts to 28 N·m (20 lb ft).




15. Connect the lower ball joints to the steering knuckles.

Tighten
Tighten the lower ball joint nuts to 75 N·m (55 lb ft).




16. Install the tie rod ends (5) to steering knuckles (4).

Tighten
Tighten the tie rod end nuts (3) to 45 N·m (33 lb ft).

17. Install the ABS electrical connectors at the cradle.
18. Install the EVO electrical connector at the cradle.
19. Install RTD electrical connectors at the cradle. (if equipped)



20. Remove J 33432-A from the vehicle.



21. With automatic transmission vehicles use the following steps:

21.1.

Remove the previously installed M10-1.5 x 55mm bolts from the front of the driveline support assembly.

21.2.

Install the plugs to the front of the driveline support assembly.

Tighten
Tighten the plugs to 35 N·m (26 lb ft).




22. Connect the automatic transmission oil cooler lines to the radiator. (if equipped)

Tighten
Tighten the cooler lines to 27 N·m (20 lb ft).




23. Connect the automatic transmission cooler lines at the engine flywheel housing junction. (if equipped)

Tighten
Tighten the automatic transmission cooler lines to 27 N·m (20 lb ft).




24. Install both electric cooling fans.
25. Install the electric cooling fan bolts.

Tighten
Tighten the electric cooling fan bolts to 10 N·m (89 lb in).




26. Connect the electrical connectors and harness to the electric cooling fans.



27. Install the front stabilizer bar to the front cradle.
28. Install the front stabilizer mounting bolts and straps.

Tighten
Tighten the front stabilizer mounting bolts to 54 N·m (40 lb ft).




29. Connect the LH front HO2S connector.
30. Connect all the grounds on the left side of the engine block.
31. Connect the engine oil temperature sensor connector.



32. Install the A/C compressor hose to the A/C compressor.
33. Install the A/C compressor line retaining bolt.

Tighten
Tighten the A/C compressor hose mounting bolts to 35 N·m (26 lb ft).




34. Connect the RH front HO2S connector.
35. Connect the crank position sensor connector.
36. Connect the oil level sensor connector.



37. Install the starter.
38. Install the starter mounting bolts.

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




39. Install all the grounds on the RH side of the engine block.
40. Connect the positive battery cable to the starter.

Tighten
Tighten positive battery cable nut to 15 N·m (11 lb ft).

41. Connect the S terminal wire to the starter.

Tighten
Tighten S terminal wire nut to 4 N·m (35 lb in).




42. Install the close-out panel.
43. Install the close-out panel bolts.

Tighten
Tighten the close-out panel bolts to 12 N·m (102 lb in).

44. Install the intermediate exhaust pipe. Refer to Intermediate Pipe in Engine Exhaust.
45. Install the front tire and wheel assemblies.

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

46. Lower the vehicle.



47. Connect the AIR hose to the LH exhaust manifold.



48. Connect the intermediate steering shaft to the steering gear.
49. Install the intermediate steering shaft bolt.

Tighten
Tighten the intermediate steering shaft bolt to 48 N·m (35 lb ft).




50. Connect the brake booster vacuum hose to the brake booster.



51. Install the generator.
52. Install the generator mounting bolts.

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




53. Install the generator rear bracket.
54. Install the generator rear bracket bolts.

Tighten
Tighten the generator rear bracket mounting bolts to 50 N·m (37 lb ft).




55. Connect the generator electrical connectors.

Tighten
Tighten the nut to 13 N·m (10 lb ft).




56. Connect the following electrical connectors:

56.1.

Fuel injectors

56.2.

Ignition coil main connectors

56.3.

EVAP solenoid

56.4.

Electric throttle motor

56.5.

Throttle position sensor

56.6.

ECT sensor

56.7.

A/C compressor




57. Connect the heater hoses to the water pump.



58. Connect the radiator hoses to the water pump.



59. Connect the fuel lines at the fuel rail. (3 and 4)



60. Install the fuel rail covers.



61. Install the generator accessory drive belt. (5)



62. Install the air intake duct and the air cleaner assembly.
63. Connect the fuel regulator purge line to the air intake duct.



64. Connect the IAT sensor connector.
65. Connect the MAF sensor connector.



66. Connect the negative battery cable.

Tighten
Tighten the negative battery cable bolt to 15 N·m (11 lb ft).

67. Fill or top off the engine with oil.
68. Refill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
69. Recharge the A/C system. Refer to Air Conditioning (A/C) Charging Using ACR4 in HVAC.
70. With automatic transmission vehicles use the following steps:

70.1.

With the flywheel hub collar bolt removed, start the engine and warm to operating temperature.

Idle or drive for at least 10 minutes.

70.2.

Shut off the engine.

70.3.

Allow engine to cool to room temperature.

70.4.

Install hub collar bolt.

Tighten
Tighten the flywheel hub collar bolt to 60 N·m (44 lb ft).

71. Check the engine for problems. Refer to Engine Set-Up and Testing .