Special Tools

1. Remove the engine cover. Refer to Engine Cover Replacement .
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
3. Recover the HVAC refrigerant. Refer to Refrigerant Recovery and Recharging .
4. Drain the cooling system. Refer to Cooling System Draining and Filling .
5. Remove the sheet metal to radiator support bolts and supports from the vehicle.
6. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
7. Remove the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement .
8. Remove the right and left headlamp capsules. Refer to Headlamp Capsule Replacement .
9. Remove the front bumper. Refer to Front Bumper Replacement .



10. Reposition the radiator inlet hose clamp (4) at the water pump.
11. Remove the radiator inlet hose from the water pump.
12. Reposition the radiator outlet hose clamp at the water pump.
13. Remove the radiator outlet hose from the water pump.



14. Disconnect the transmission cooler lines from the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection .
15. Disconnect the oil cooler line from the radiator, if equipped.
16. Disconnect the HVAC lines from the condenser.
17. Disconnect the ground G106 from the right hand inner fender. Refer to Ground Distribution Schematics .
18. Disconnect the C4 at the underhood fuse block. Refer to Power Distribution Schematics .
19. Disconnect the positive battery cable from the underhood fuse block and position aside.



20. Remove the core support retaining bolt (3).
21. With the aid of an assistant, remove the core support assembly with the radiator, condenser radiator hoses and fan shroud intact.
22. Remove the clutch fan. Refer to Fan Clutch Replacement .
23. Remove the accessory drive belt.
24. 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.




25. Remove the radiator vent inlet hose (1) from the throttle body.



26. Remove the ground strap from the frame and engine.



27. Remove G104 and G105 from the engine. Refer to Ground Distribution Schematics .
28. Remove the air conditioning compressor. Refer to Air Conditioning Compressor Replacement .
29. Disconnect the heater hoses from the water pump.
30. Remove the intake manifold. Refer to Intake Manifold Removal .
31. Remove the ignition coils from the engine. Refer to Ignition Coil Replacement .
32. Remove the coolant air bleed pipe from the engine. Refer to Coolant Air Bleed Pipe Assembly Replacement .
33. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
34. Remove the oil drain plug and drain the oil into a suitable container.
35. Remove the starter motor. Refer to Starter Motor Replacement .
36. Disconnect the catalytic converter pipe from the exhaust manifolds. Refer to Catalytic Converter Replacement .
37. Disconnect the following electrical connectors:

•	The crankshaft position (CKP) sensor

•	The engine oil level sensor

•	The coolant heater, if equipped




38. Unclip the battery positive cable (2) from the harness clip.
39. Gather all branches of the engine wiring harness and reposition off to the side.



40. Remove the lower 6 bell housing to engine studs and bolts. Leave the top 2 studs in place.



41. Remove the torque converter bolts.
42. Lower the vehicle.
43. Remove the left and right exhaust manifolds.

Notice: Refer to Fastener Notice in the Preface section.

44. Install the J 42451-1 to the cylinder heads.

Tighten
Tighten the M10 engine lift bracket bolts to 50 N·m (37 lb ft).




45. Remove the left and right engine mount-to-engine mount bracket bolts.



46. Remove the transmission oil level indicator tube nut.



47. Remove the transmission oil level indicator tube.



48. Remove the top 2 automatic transmission studs.
49. Install a floor jack under the transmission for support.
50. Install an engine hoist to the J 42451-1 .
51. Separate the engine from the automatic transmission, if equipped.

Install the J 21366 to the transmission in order to hold the torque converter.

52. Remove the engine.
53. Install the engine to an engine stand.
54. Remove the engine hoist.
55. Remove the J 42451-1 from the engine.

1. Install the J 42451-1 to the engine.

Tighten
Tighten the M10 engine lift bracket bolts to 50 N·m (37 lb ft).

2. Install an engine hoist to the J 42451-1 .
3. Remove the engine from the engine stand.
4. Install the engine to the vehicle.
5. Align the engine and transmission.



6. Install the left and right engine mount-to-engine mount bracket bolts.

Tighten
Tighten the engine mount-to-engine mount bracket bolts to 60 N·m (44 lb ft).

7. Install the upper transmission bolts until snug.
8. Remove the floor jack from under the transmission.
9. Remove the engine hoist.
10. Remove the J 42451-1 from the engine.
11. Install the left and right exhaust manifolds. Refer to Exhaust Manifold Installation - Left Side and to Exhaust Manifold Installation - Right Side .
12. Install the intake manifold. Refer to Intake Manifold Installation .
13. Install the ignition coil(s) and the spark plug wire(s). Refer to Ignition Coil Replacement .
14. Raise the vehicle.



15. Remove the J 21366 from the transmission.
16. Install the automatic transmission bolt/studs, if equipped.



17. Install the torque converter bolts, if equipped.

Tighten

•	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).




18. If equipped with the 4L80-E automatic transmission, install the transmission converter cover bolts.

Tighten
Tighten the transmission converter cover bolts to 33 N·m (24 lb ft).




19. If equipped with the 4L60-E automatic transmission, install the transmission bolt and stud on the right side.

Tighten
Tighten the automatic transmission bolts/studs to 50 N·m (37 lb ft).




20. Install the automatic transmission oil level indicator tube, if equipped.



21. Install the automatic transmission oil level indicator tube nut, if equipped.

Tighten
Tighten the automatic transmission oil level indicator tube nut to 18 N·m (13 lb ft).




22. Install the positive battery cable clip (1).
23. Install the catalytic converter. Refer to Catalytic Converter Replacement .
24. Connect the following electrical connectors:

•	Crankshaft position sensor

•	Engine oil level sensor

•	Coolant heater, if equipped

25. Install the starter motor. Refer to Starter Motor Replacement .
26. Lower the vehicle.
27. Position the generator bracket assembly to the front of the engine.
28. Install the generator bracket assembly. Refer to Generator Bracket Replacement .
29. Install the heater hoses to the water pump.



30. Install the air conditioning compressor (2) to the engine.

Tighten
Tighten the compressor mounting bolts to 68 N·m (50 lb ft).

31. Install the air conditioning discharge hose to the compressor.

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

32. Install the engine ground strap to the frame.

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

33. Install the ground strap and negative battery cable to the engine.

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

34. Install the clutch fan. Refer to Fan Clutch Replacement .



35. With the aid of an assistant, position the core support assembly to the vehicle.
36. Install the core support bolts.

Tighten

•	Tighten the core support bolts to 25 N·m (18 lb ft).

•	Tighten the core support nuts to 57 N·m (42 lb ft).

37. Install the positive battery cable to the underhood fuse panel.

Tighten
Tighten the bolt to 12 N·m (106 lb in).

38. Install the G106 to the inner fender. Refer to Ground Distribution Schematics .

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

39. Connect the C4 to the underhood fuse panel. Refer to Power Distribution Schematics .



40. Install the air conditioning lines (2) to the condenser.

Tighten
Tighten the remaining nuts to 16 N·m (12 lb ft).




41. Install the transmission cooler lines to the radiator.
42. Install the oil cooler lines to the radiator, if equipped.
43. Install the radiator hoses to the thermostat housing and water pump.



44. Install the headlamp capsules (4). Refer to Headlamp Capsule Replacement .



45. Install the front bumper. Refer to Front Bumper Replacement .
46. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
47. Install the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement .
48. Install the sheet metal to the fender supports.

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

49. Fill the cooling system with coolant. Refer to Cooling System Draining and Filling .
50. Fill the crankcase with the proper quantity and grade of engine oil. Refer to Approximate Fluid Capacities or Fluid and Lubricant Recommendations .
51. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn .

Important: 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.

52. Close the hood.