Special Tools
Removal Procedure
- Remove the engine cover. Refer to
Engine Cover Replacement.
- Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection.
- Recover the HVAC refrigerant. Refer to
Refrigerant Recovery and Recharging.
- Drain the cooling system. Refer to
Cooling System Draining and Filling.
- Remove the sheet metal to radiator support bolts and supports from the vehicle.
- Remove the air cleaner assembly. Refer to
Air Cleaner Assembly Replacement.
- Remove the coolant reservoir. Refer to
Coolant Recovery Reservoir Replacement.
- Remove the right and left headlamp capsules. Refer to
Headlamp Capsule Replacement.
- Remove the front bumper. Refer to
Front Bumper Replacement.
- Reposition the radiator inlet hose clamp (4) at the water pump.
- Remove the radiator inlet hose from the water pump.
- Reposition the radiator outlet hose clamp at the water pump.
- Remove the radiator outlet hose from the water pump.
- Disconnect the transmission cooler lines from the radiator. Refer to
Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection.
- Disconnect the oil cooler line from the radiator, if equipped.
- Disconnect the HVAC lines from the condenser.
- Disconnect the ground G106 from the right hand inner fender. Refer to
Ground Distribution Schematics.
- Disconnect the C4 at the underhood fuse block. Refer to
Power Distribution Schematics.
- Disconnect the positive battery cable from the underhood fuse block and position aside.
- Remove the core support retaining bolt (3).
- With the aid of an assistant, remove the core support assembly with the radiator, condenser radiator hoses and fan shroud intact.
- Remove the clutch fan. Refer to
Fan Clutch Replacement.
- Remove the accessory drive belt.
- Remove the generator bracket from the engine. Refer to
Generator Bracket Replacement.
Leave the generator and power steering pump retained to the bracket. Use a suitable strap and position the bracket assembly aside.
- Remove the radiator vent inlet hose (1) from the throttle body.
- Remove the ground strap from the frame and engine.
- Remove G104 and G105 from the engine. Refer to
Ground Distribution Schematics.
- Remove the air conditioning compressor. Refer to
Air Conditioning Compressor Replacement.
- Disconnect the heater hoses from the water pump.
- Remove the intake manifold. Refer to
Intake Manifold Removal.
- Remove the ignition coils from the engine. Refer to
Ignition Coil Replacement.
- Remove the coolant air bleed pipe from the engine. Refer to
Coolant Air Bleed Pipe Assembly Replacement.
- Raise the vehicle. Refer to
Lifting and Jacking the Vehicle.
- Remove the oil drain plug and drain the oil into a suitable container.
- Remove the starter motor. Refer to
Starter Motor Replacement.
- Disconnect the catalytic converter pipe from the exhaust manifolds. Refer to
Catalytic Converter Replacement.
- Disconnect the following electrical connectors:
• | The crankshaft position (CKP) sensor |
• | The engine oil level sensor |
• | The coolant heater, if equipped |
- Unclip the battery positive cable (2) from the harness clip.
- Gather all branches of the engine wiring harness and reposition off to the side.
- Remove the lower 6 bell housing to engine studs and bolts. Leave the top 2 studs in place.
- Remove the torque converter bolts.
- Lower the vehicle.
- Remove the left and right exhaust manifolds.
Caution: Refer to Fastener Caution in the Preface section.
- Install the
J 42451-1 to the cylinder heads. Tighten the M10 engine lift bracket bolts to
50 N·m (37 lb ft).
- Remove the left and right engine mount-to-engine mount bracket bolts.
- Remove the transmission oil level indicator tube nut.
- Remove the transmission oil level indicator tube.
- Remove the top 2 automatic transmission studs.
- Install a floor jack under the transmission for support.
- Install an engine hoist to the
J 42451-1 .
- Separate the engine from the automatic transmission, if equipped.
Install the
J 21366 to the transmission in order to hold the torque converter.
- Remove the engine.
- Install the engine to an engine stand.
- Remove the engine hoist.
- Remove the
J 42451-1 from the engine.
Installation Procedure
- Install the
J 42451-1 to the engine. Tighten the M10 engine lift bracket bolts to
50 N·m (37 lb ft).
- Install an engine hoist to the
J 42451-1 .
- Remove the engine from the engine stand.
- Install the engine to the vehicle.
- Align the engine and transmission.
- Install the left and right engine mount-to-engine mount bracket bolts and tighten to
60 N·m (44 lb ft).
- Install the upper transmission bolts until snug.
- Remove the floor jack from under the transmission.
- Remove the engine hoist.
- Remove the
J 42451-1 from the engine.
- Install the left and right exhaust manifolds. Refer to
Exhaust Manifold Installation - Left Side and to
Exhaust Manifold Installation - Right Side.
- Install the intake manifold. Refer to
Intake Manifold Installation.
- Install the ignition coil(s) and the spark plug wire(s). Refer to
Ignition Coil Replacement.
- Raise the vehicle.
- Remove the
J 21366 from the transmission.
- Install the automatic transmission bolt/studs, if equipped.
- Install the torque converter bolts, if equipped.
• | If equipped with the 4L60-E, tighten the torque converter bolts to
63 N·m (46 lb ft). |
• | If equipped with the 4L80-E, tighten the torque converter bolts to
60 N·m (44 lb ft). |
- If equipped with the 4L80-E automatic transmission, install the transmission converter cover bolts and tighten to
33 N·m (24 lb ft).
- If equipped with the 4L60-E automatic transmission, install the transmission bolt and stud on the right side and tighten to
50 N·m (37 lb ft).
- Install the automatic transmission oil level indicator tube, if equipped.
- Install the automatic transmission oil level indicator tube nut and tighten to
18 N·m (13 lb ft), if equipped.
- Install the positive battery cable clip (1).
- Install the catalytic converter. Refer to
Catalytic Converter Replacement.
- Connect the following electrical connectors:
• | Crankshaft position sensor |
• | Engine oil level sensor |
• | Coolant heater, if equipped |
- Install the starter motor. Refer to
Starter Motor Replacement.
- Lower the vehicle.
- Position the generator bracket assembly to the front of the engine.
- Install the generator bracket assembly. Refer to
Generator Bracket Replacement.
- Install the heater hoses to the water pump.
- Install the air conditioning compressor (2) to the engine. Tighten the compressor mounting bolts to
68 N·m (50 lb ft).
- Install the air conditioning discharge hose to the compressor. Tighten the bolt to
35 N·m (26 lb ft).
- Install the engine ground strap to the frame. Tighten the bolt to
25 N·m (18 lb ft).
- Install the ground strap and negative battery cable to the engine. Tighten the nut to
25 N·m (18 lb ft).
- Install the clutch fan. Refer to
Fan Clutch Replacement.
- With the aid of an assistant, position the core support assembly to the vehicle.
- Install the core support bolts.
• | Tighten the core support bolts to
25 N·m (18 lb ft). |
• | Tighten the core support nuts to
57 N·m (42 lb ft). |
- Install the positive battery cable to the underhood fuse panel. Tighten the bolt to
12 N·m (106 lb in).
- Install the G106 to the inner fender. Refer to
Ground Distribution Schematics. Tighten the bolt to
10 N·m (89 lb in).
- Connect the C4 to the underhood fuse panel. Refer to
Power Distribution Schematics.
- Install the air conditioning lines (2) to the condenser. Tighten the remaining nuts to
16 N·m (12 lb ft).
- Install the transmission cooler lines to the radiator.
- Install the oil cooler lines to the radiator, if equipped.
- Install the radiator hoses to the thermostat housing and water pump.
- Install the headlamp capsules (4). Refer to
Headlamp Capsule Replacement.
- Install the front bumper. Refer to
Front Bumper Replacement.
- Install the air cleaner assembly. Refer to
Air Cleaner Assembly Replacement.
- Install the coolant reservoir. Refer to
Coolant Recovery Reservoir Replacement.
- Install the sheet metal to the fender supports. Tighten the bolts to
25 N·m (18 lb ft).
- Fill the cooling system with coolant. Refer to
Cooling System Draining and Filling.
- Fill the crankcase with the proper quantity and grade of engine oil. Refer to
Approximate Fluid Capacities or
Fluid and Lubricant Recommendations.
- Perform the CKP system variation learn procedure. Refer to
Crankshaft Position System Variation Learn.
Note: After an overhaul, the engine should be tested. Use the following procedure after the engine is installed in the vehicle.
51.1. | Disable the ignition system. |
51.2. | Crank the engine several times. Listen for any unusual noises or evidence that parts are binding. |
51.3. | Enable the ignition system. |
51.4. | Start the engine and listen for unusual noises. |
51.5. | Check the vehicle oil pressure gage or light and confirm that the engine has acceptable oil pressure. |
51.6. | Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature. |
51.7. | Listen for sticking lifter and other unusual noises. |
51.8. | Inspect for fuel, oil and/or coolant leaks while the engine is running. |
51.9. | Perform a final inspection for the proper engine oil and coolant levels. |
- Close the hood.