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Engine Assembly

Removal & Installation

To Remove:

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Relieve the fuel system pressure.
  3. Disconnect the negative battery cable.
  4. Drain the engine cooling system.
  5. Remove the hood, air cleaner outlet tube, and accelerator control splash shield.
  6. Remove the upper and lower radiator hoses.
  7. Remove the bolts and place the fan shroud onto the fan blade.
  8. Remove the water pump pulley, fan, and shroud.
  9. Disconnect the radiator overflow tube.
  10. If vehicle has automatic transmission, disconnect the transmission cooler lines.
  11. Disconnect the mass air flow sensor and the heater water hoses at the inlet and outlet.
  12. Disconnect the power connector from the generator.
  13. Disconnect the vacuum connector from the vacuum reservoir.
  14. Disconnect the throttle body heater hose.
  15. Disconnect the A/C cycling switch.
  16. Disconnect the connector from the powertrain control module (PCM) and remove the nut.
  17. Remove the ground wire stud from the PCM.
  18. Recover the A/C system.
  19. Disconnect the power steering cut-out switch.
  20. Disconnect the peanut fitting from the A/C condenser core.
  21. Disconnect the A/C high pressure cut-out switch and the A/C manifold hose then remove the nut.
  22. Disconnect the accelerator cable and speed control cable.
  23. Disconnect the brake booster vacuum hose and vacuum tube at the upper intake manifold assembly.
  24. Disconnect the EVR vacuum supply hose and the vacuum reservoir vacuum line.
  25. Disconnect the wiring connector and the fuel line.
  26. Remove the A/C compressor.
  27. Disconnect the power steering pressure and return hoses.
  28. Remove the nut that retains the wiring harness.
  29. Disconnect the block heater, if present.
  30. Safely raise and support the vehicle then disconnect the engine ground cable.
  31. If vehicle has automatic transmission, disconnect the connectors for the transmission harness. If vehicle has manual transmission, disconnect the transmission harness and heated oxygen sensor (HO2S).
  32. Remove the starter motor.
  33. Remove the nut that retains the starter harness and transmission cooler brackets.
  34. Disconnect the three-way catalytic converter (TWC).

    NOTE: The torque converter nuts can be accessed through the starter hole.

  35. If vehicle has automatic transmission, remove the torque converter nuts.

    NOTE: Before engine removal, look for shims that may be located at the bottom of the block. If you find these, make sure to install the shims with the engine.

  36. Remove the 6 bolts.
  37. Lower the vehicle.
  38. Support the transmission with a floor jack.
  39. Remove the differential pressure feedback EGR sensor.
  40. Support the engine with a floor crane.
  41. Remove the upper transmission-to-engine bolts.
  42. If vehicle has automatic transmission, disconnect then separate the connector for the heated exhaust gas oxygen sensor from the bracket located on the bell housing.
  43. Remove the 4 nuts then remove the engine from the vehicle.
  44. If vehicle has manual transmission, remove the clutch.
  45. Remove the flywheel.
  46. Mount the engine on an appropriate work stand.

To Install:

  1. Remove the engine from the stand.
  2. Install the flywheel. Torque to 54-64 ft-lb (73-87 Nm).
  3. If vehicle has manual transmission, install the clutch.
  4. Place the engine into the vehicle and install the nuts. Torque to 65-85 ft-lb (88-115 Nm).
  5. Connect the connectors for the heated exhaust gas oxygen sensor.
  6. Install the upper transmission-to-engine bolts.
  7. Remove the floor crane.
  8. Install the EGR transducer.
  9. Remove the floor jack from the transmission.
  10. Safely raise and support the vehicle.
  11. Install the 6 bolts. Torque to 23-39 ft-lb (38-51 Nm).

    NOTE: Install the nuts through the starter hole.

  12. Install the nuts that retain the torque converter to the flywheel.
  13. Connect the TWC to the starter then connect the connectors for the transmission wiring harness.
  14. Connect the engine ground cable and bolt. Torque to 71-106 in-lb (8-12 Nm).
  15. Lower the vehicle.
  16. If present, connect the block heater cable to the block heater.
  17. Connect the engine sensor control wiring harness to the A/C high pressure cut-out switch.
  18. Connect the A/C manifold to the A/C evaporator core. Torque to 60.6-82 in-lb (6.8-9.2 Nm).
  19. Connect the engine sensor control wiring harness to the power steering cut-out switch.
  20. Install the nut. Torque to 71-106 in-lb (8-12 Nm).
  21. Connect the power steering pressure and the return hoses. Torque to 13-17 ft-lb (17-23 Nm).
  22. Install the A/C compressor.
  23. Connect the engine sensor control wiring harness to the A/C compressor then connect the fuel line.
  24. Connect the 42-pin connector. Torque to 71-106 in-lb (8-12 Nm).
  25. Connect the EVR vacuum supply hose and the vacuum reservoir vacuum line.
  26. Connect the brake booster vacuum hose and the vacuum tube.
  27. Connect the accelerator cable.
  28. Install the ground strap. Torque to 71-106 in-lb (8-12 Nm).
  29. Connect the A/C manifold hose.
  30. Install the PCM ground strap. Torque to 80-106 in-lb (9-12 Nm).
  31. Install the PCM wiring harness bracket bolt.
  32. Connect the engine sensor control wiring harness to the PCM. Torque to 45-61 in-lb (5-7 Nm).
  33. Connect the engine control sensor wiring harness to the A/C low pressure cut-out switch.
  34. Connect the throttle body heater hose.
  35. Connect the vacuum hose to the vacuum reservoir.
  36. Install the fan clutch. Torque bolts to 13-17 ft-lb (17-23 Nm).
  37. Install the drive belt.
  38. Connect the cable to the generator then connect the heater water hoses at the outlet and inlet tubes.
  39. Connect the fuel charging wiring, the radiator, and the fan shroud then install the bolts.
  40. If vehicle has automatic transmission, connect the transmission fluid cooler hoses.
  41. Connect the radiator overflow hose.
  42. Install the lower and upper radiator hoses.
  43. Install the accelerator control splash shield. Torque to 62-79 in-lb (7-9 Nm).
  44. Install the air cleaner outlet tube and the hood.
  45. Connect the negative battery cable.
  46. Fill and bleed the cooling system and the power steering system.
  47. Fill the transmission.
  48. Charge the A/C system.

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