Special Tools

1. Remove the hood. Refer to Hood Replacement.
2. Recover the A/C system. Refer to Refrigerant Recovery and Recharging.
3. Remove the drive belt. Refer to Drive Belt Replacement.
4. Remove the battery box. Refer to Battery Box Replacement.
5. Drain the engine coolant. Refer to Cooling System Draining and Filling.
6. Remove the outlet radiator hose. Radiator Outlet Hose Replacement.
7. Remove the radiator. Refer to Radiator Replacement.
8. Remove the cooling fan. Refer to Fan Replacement.
9. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
10. Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement.



11. Position the J 38185 to the clamp (3) in order to remove the radiator inlet hose (2) from the water outlet housing (4).
12. Remove the washer solvent container/coolant recovery reservoir mounting bolts ONLY, in order to gain clearance to remove the engine wiring harness. Refer to Windshield Washer Solvent Container Replacement.



13. Disconnect the 2 engine wiring harness connectors from the powertrain control module (PCM).
14. Remove the engine wiring harness clips from the wheelhouse.



15. Disconnect the engine wiring harness retainers (1) from the power steering pump (2).
16. Disconnect the engine wiring harness connectors from the following components:

•	The electric motor actuator connector

•	The oil pressure switch




17. Disconnect the engine wiring harness retainer (2) from the camshaft cover (3).
18. Disconnect the engine wiring harness connectors from the following components:

•	The exhaust camshaft position (CMP) sensor (5)

•	The exhaust camshaft actuator (6)




19. Disconnect the engine wiring harness connectors from the following components:

•	The engine coolant temperature (ECT) sensor (1)

•	The fuel injector harness (2)

•	The ignition coils (4)

•	The heated oxygen sensor (HO2S) (5)




20. Disconnect the engine wiring harness retainer (3) from the camshaft cover (4).
21. Disconnect the engine wiring harness connector (2) from the throttle body (1).



22. Disconnect the engine wiring harness connector from the intake CMP sensor.



23. Carefully disengage the engine wiring harness conduit from the camshaft cover.
24. Remove the transmission filler tube, if equipped. Refer to Transmission Fluid Filler Tube and Seal Replacement.



25. Remove the air conditioning (A/C) compressor evaporator hose bracket bolt from the cylinder head.
26. Drain the engine oil, if necessary. Refer to Engine Oil and Oil Filter Replacement.



27. Remove the studs securing the secondary air injection (AIR) pipe cover to the cylinder head.

Remove the AIR pipe cover and gasket.

Discard the gasket.




28. Install the J 44220 in place of the AIR adapter.



29. Disconnect the inlet heater hose quick connect (1) from the heater core (2), and secure to the engine.



30. Remove the power steering pump mounting bolts ONLY, and position aside.



31. Remove the right engine mount-to-frame bracket bolt.



32. Disconnect the engine wiring harness retainer from the engine wiring harness bracket.
33. Position the engine wiring harness aside.
34. Disconnect the fuel feed pipe from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service.
35. Disconnect the evaporative emission (EVAP) pipe at the purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service.
36. Remove the oil level indicator and tube. Refer to Oil Level Indicator Tube Replacement.



37. Remove the manifold absolute pressure (MAP) sensor. Refer to Manifold Absolute Pressure Sensor Replacement.
38. Disconnect the MAP sensor wiring harness retainer (4) from the intake manifold.
39. Raise and support the vehicle only high enough to access the wiring harnesses through the wheelhouse. Refer to Lifting and Jacking the Vehicle.



40. Remove the A/C condenser line bolt at the A/C compressor, remove the line from the compressor, if equipped.



41. Remove the A/C evaporator line bolt at the A/C compressor, remove the line from the compressor, if equipped.



42. Remove the A/C compressor bolts and compressor, if equipped.



43. Disconnect the following wiring harness retainers from the engine wiring harness bracket:

•	The battery cable

•	The engine (4, 6)

•	The MAP sensor (5)




44. Remove the starter solenoid "S" terminal nut (3) and disconnect the lead (4) from the starter.
45. Remove the starter terminal nut (1) and disconnect the battery positive cable (2) from the starter.



46. Remove the bolt (5) securing the battery negative cable ground terminal (4) to the engine block.



47. Disconnect the engine wiring harness connector from the EVAP canister purge solenoid valve.



48. Disconnect the engine wiring harness connector (3) from the number 2 knock sensor (KS) (1).
49. Disconnect the coolant heater cord from the coolant heater, if equipped.



50. Disconnect the engine wiring harness retainers (1, 2) from the A/C compressor and the engine oil pan rail.



51. Position the J 38185  (2) to the clamp (1) in order to remove the heater outlet hose from the heater outlet hose fitting (3).



52. Disconnect the engine wiring harness connector (3) from the crankshaft position (CKP) sensor (1).
53. Raise the vehicle completely. Refer to Lifting and Jacking the Vehicle.
54. Remove the 3 bolts securing the engine wiring ground leads (2) to the engine block.
55. Disconnect the engine wiring harness retainer (5) from the engine oil pan rail.
56. Position the engine wiring harness aside.



57. Disconnect the fuel line clips from the brackets on the transmission.



58. Remove the crossmember. Refer to Crossmember Replacement.
59. Remove the front propeller shaft. Refer to Front Propeller Shaft Replacement.



60. Remove the differential carrier assembly bushing to frame bolts ONLY.
61. Position the differential carrier assembly forward.
62. Secure the pinion yoke, in order to prevent the differential carrier from rotating.
63. Remove the exhaust seal. Refer to Exhaust Seal Replacement.



64. Remove the bolt (2) securing the transmission oil cooler pipe bracket to the right side of the engine oil pan rail (automatic only).



65. Remove the inspection plug (3) from the transmission (1) (M30 only).
66. Mark the torque converter to flexplate/flywheel orientation to ensure proper realignment (M30 only).



67. Remove the service slot plug.
68. Repeat the following steps for all 3 torque converter bolts (automatic only):

68.1.

Rotate the harmonic balancer center bolt clockwise ONLY, in order to access the torque converter bolt through the service slot.

68.2.

Remove the torque converter bolts.




69. Lower the transmission slightly.
70. Remove the 9 transmission bolts.



71. Lower the vehicle.
72. Remove the left engine mount-to-frame bracket bolt.



73. Place a jack under the transmission for support.
74. Remove the remaining transmission mounting bolts (2).



75. Install an engine lift chain to the engine lift brackets and attach to an engine lift device.
76. Using the engine lift device, raise the engine only enough to remove the engine mounts.
77. Remove the bolts securing the following to the engine block:

•	The left engine mount

•	The right engine mount

78. Remove the engine mounts.

Note: Ensure clearance is maintained between the engine and the following:

•	The A/C compressor

•	The A/C hoses

•	The engine mounts

•	The engine wiring harness

•	The fuel hose/pipes

•	The heater outlet hose/pipe

•	The power steering pump

•	The transmission input shaft (manual only)

•	The transmission oil cooler pipes (automatic only)

79. Carefully raise the engine from the engine compartment, ensuring the transmission stays supported.
80. Install the engine to an engine stand.
81. Remove the engine lift chain from the engine lift brackets.

1. Install an engine lift chain to the engine lift brackets and attach to an engine lift device.
2. Remove the engine from the engine stand.
3. Ensure the torque converter is fully engaged with the transmission oil pump (M30 only).
4. Position the engine mounts to the engine.
5. Install the engine mount bolts until snug, following the installation sequence.

The engine lift device may have to be raised or lowered slightly to install these bolts.

Caution: Refer to Fastener Caution in the Preface section.

6. Tighten the bolts using the installation sequence to 50 N·m (37 lb ft).




Note: Ensure clearance is maintained between the engine and the following:

•	The A/C compressor

•	The A/C hoses

•	The engine mounts

•	The engine wiring harness

•	The fuel hose/pipes

•	The heater outlet hose/pipe

•	The power steering pump

•	The transmission input shaft (manual only)

•	The transmission oil cooler pipes (automatic only)

7. Carefully lower the engine into the engine compartment, aligning the engine dowels with the transmission.




Note: Ensure the torque converter turns freely while tightening the transmission mounting bolts (automatic only).

8. Align the engine dowels (1) with the transmission.
9. Loosely install the 2 transmission mounting bolts (2).

Ensure the dowels (1) are fully engaged into the transmission.

10. Remove the jack from under the vehicle.
11. Lower the engine fully on to the engine mounts.
12. Remove the engine lift chain from the engine lift brackets.
13. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.



14. Tighten the 2 transmission mounting bolts (2) previously installed to 50 N·m (37 lb ft).




Note: 

•	Ensure the studded mounting bolts (2) are located in the correct position.

•	The heater pipe (1) must be secured with the 2 upper mounting bolts.

15. Install the remaining transmission mounting bolts and tighten to 50 N·m (37 lb ft).
16. Align the torque converter to flexplate/flywheel orientation marks made during the removal procedure (automatic only).
17. Repeat the following steps for all 3 torque converter bolts (automatic only):

17.1.

Rotate the harmonic balancer center bolt clockwise ONLY, in order to access the torque converter bolt holes in the flexplate/flywheel through the service slot.

17.2.

To aid in alignment of the torque converter to the flexplate/flywheel, install all 3 torque converter bolts before fully tightening. Tighten the torque converter bolts to 60 N·m (44 lb ft).




18. Install the inspection plug (3) to the transmission (1) (automatic only).



19. Install the bolt (2) securing the transmission oil cooler pipe bracket to the right side of the engine oil pan rail (automatic only).

Tighten the transmission oil cooler pipe bracket bolt to 20 N·m (15 lb ft).

20. Install the exhaust seal. Refer to Exhaust Seal Replacement.



21. Install the service slot plug.
22. Install the crossmember. Refer to Crossmember Replacement.



23. Position the differential carrier assembly to the frame.
24. Install the differential carrier assembly bushing to frame bolts and tighten to 152 N·m (112 lb ft).
25. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement.



26. Install the fuel line clips to the brackets on the transmission (automatic only).

Tighten the fuel hose/pipe bracket nuts to 20 N·m (15 lb ft).




27. Install the fuel line clips to the brackets on the transmission (manual only).

Tighten the fuel hose/pipe bracket nuts to 20 N·m (15 lb ft).




28. Connect the engine wiring harness retainer (5) to the engine oil pan rail.
29. Install the 3 bolts securing the engine wiring ground leads (2) to the engine block Tighten the bolts to 20 N·m (15 lb ft).
30. Lower the vehicle to chest level in order to access the components through the wheelhouse.
31. Connect the engine wiring harness connector (3) to the CKP sensor (1).



32. Install the A/C compressor and bolts to 50 N·m (37 lb ft), if equipped.



33. Install the A/C evaporator line to the compressor and install the bolt at the A/C compressor, if equipped.

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




34. Install the A/C condensor line to the compressor and install the bolt at the A/C compressor, if equipped.

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




35. Position the J 38185  (2) to the clamp (1) in order to connect the heater outlet hose to the heater outlet hose fitting (3).



36. Connect the engine wiring harness retainers (1, 2) to the A/C compressor and the engine oil pan rail.



37. Connect the engine wiring harness connector (3) to the number 2 KS (1).
38. Connect the coolant heater cord to the coolant heater, if equipped.



39. Connect the engine wiring harness connector to the EVAP canister purge solenoid valve.



40. Install the bolt (5) securing the battery negative cable ground terminal  (4) to the engine block and tighten the bolt to 35 N·m (26 lb ft).



41. Connect the battery positive cable (2) to the starter and install the starter terminal nut (1) and tighten the nut to 9 N·m (80 lb in).
42. Connect the lead (4) to the starter solenoid and install the starter solenoid "S" terminal nut (3).

Tighten the starter solenoid "S" terminal nut to 3.5 N·m (31 lb in).




43. Secure the following wiring harness retainers to the engine wiring harness bracket:

•	The battery cable

•	The engine (4, 6)

•	The MAP sensor (5)

44. Lower the vehicle.



45. Install the left engine mount-to-frame bracket bolt and tighten to 85 N·m (63 lb ft).



46. Connect the MAP sensor wiring harness retainer (4) to the intake manifold.
47. Install the MAP sensor. Refer to Manifold Absolute Pressure Sensor Replacement.
48. Install the oil level indicator and tube. Refer to Oil Level Indicator Tube Replacement.
49. Connect the EVAP pipe at the purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service.
50. Connect the fuel feed pipe to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service.



51. Connect the engine wiring harness retainer to the engine wiring harness bracket.



52. Install the right engine mount-to-frame bracket bolt and tighten to 85 N·m (63 lb ft).



53. Position the power steering pump to the power steering pump bracket.
54. Install the power steering pump mounting bolts and tighten to 25 N·m (18 lb ft).



55. Connect the inlet heater hose quick connect (1) to the heater core (2).



56. Remove the J 44220 from the cylinder head.



57. Position the AIR pipe cover and NEW gasket to the cylinder head.
58. Install the AIR pipe cover studs and tighten to 25 N·m (18 lb ft).
59. Install the transmission filler tube, if equipped. Refer to Transmission Fluid Filler Tube and Seal Replacement.



60. Position the A/C compressor evaporator hose bracket to the cylinder head and install the bolt. Tighten the bolt to 9 N·m (80 lb in).



61. Engage the engine wiring harness conduit to the camshaft cover.



62. Connect the engine wiring harness connector to the Intake CMP sensor.



63. Connect the engine wiring harness retainer (3) to the camshaft cover (4).
64. Connect the engine wiring harness connector (2) to the throttle body (1).



65. Connect the engine wiring harness connectors to the following components:

•	The ECT sensor (1)

•	The fuel injector harness (2)

•	The ignition coils (4)

•	The HO2S (5)




66. Connect the engine wiring harness retainer (2) to the camshaft cover (3).
67. Connect the engine wiring harness connectors to the following components:

•	The exhaust CMP sensor (5)

•	The exhaust camshaft actuator (6)




68. Connect the engine wiring harness retainers (1) to the power steering pump (2).
69. Connect the engine wiring harness connectors to the following components:

•	The electric motor actuator connector (4WD only)

•	The oil pressure switch




70. Connect the engine wiring harness retainers to the wheelhouse.
71. Connect the 2 engine wiring harness connectors to the PCM.
72. Install the washer solvent container/coolant recovery reservoir mounting bolts. Refer to Windshield Washer Solvent Container Replacement.
73. Install the radiator. Refer to Radiator Replacement.



74. Position the J 38185 to the clamp (3) in order to connect the radiator inlet hose (2) to the water outlet housing (4).
75. Install the generator. Refer to Generator Replacement.
76. Install the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement.
77. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
78. Install the cooling fan. Refer to Fan Replacement.
79. Install the outlet radiator hose. Refer to Radiator Outlet Hose Replacement.
80. Fill the cooling system. Refer to Cooling System Draining and Filling.
81. Install the battery box. Refer to Battery Box Replacement.
82. Install the hood. Refer to Hood Replacement.
83. Fill the engine oil, if previously drained. Refer to Engine Oil and Oil Filter Replacement.
84. Charge the A/C system. Refer to Refrigerant Recovery and Recharging.

Complete the following procedure after the engine is installed in the vehicle:

1. With the ignition OFF or disconnected, crank the engine several times. Listen for any unusual noises or evidence that any parts are binding.
2. Start the engine and listen for abnormal conditions.
3. Check the vehicle oil pressure gage or light and confirm that the engine has acceptable oil pressure.
4. Run the engine at approximately 1,000 RPM until the engine reaches normal operating temperature.
5. While the engine continues to idle raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
6. Inspect for oil, coolant, transmission fluid, and exhaust leaks while the engine is idling.
7. Lower the vehicle.
8. Perform the CKP variation learn procedure. Refer to Crankshaft Position System Variation Learn.
9. Perform a final inspection for the proper engine oil, transmission fluid and coolant levels.
10. Road test the vehicle.