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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. Drain the cooling system and the engine oil.
  4. Drain the engine oil.
  5. Properly discharge the A/C system (if present).
  6. Disconnect the negative battery cable.
  7. Remove the hood and the air cleaner outlet pipe.
  8. Remove the lower radiator hose.
  9. Drain the engine oil. Torque fastener to 19 ft-lb (26 Nm).
  10. Release the transmission cooler tubes from the clips on the bottom of the radiator.
  11. Remove the starter motor.
  12. Disconnect the right and left exhaust pipes from the exhaust manifolds.
  13. If present, remove the torque converter nuts.
  14. Remove the transmission-to-oil-pan bolts and the transmission-to-engine bolts.
  15. Disconnect the wiring harness retainers and the electrical connectors for the transmission.
  16. Disconnect the electrical connector for the catalyst monitor and detach the connector from the bracket.
  17. If present, remove the engine damper bolt.

    NOTE: It may be easier to access the nuts and bolts if you partially lower the vehicle and work through the opening of the right wheel well.

  18. Remove the transmission cooler tube bracket bolt and right motor mount nuts.
  19. Lower the vehicle.
  20. Remove the upper radiator hose.
  21. Remove the bolts and place the fan shroud onto the fan blade.
  22. If present, disconnect the transmission cooler tubes.
  23. Disconnect the coolant recovery hose.
  24. Remove the radiator bolts, radiator, and fan shroud.
  25. Disconnect the peanut fitting on the A/C discharge tube.
  26. Disconnect the A/C compressor clutch and the electrical connectors for the high pressure cut-off switch.
  27. Disconnect the A/C manifold and tube from the suction accumulator/drier.
  28. Disconnect the B+ wiring lead from the generator then disconnect the power steering pressure and return tubes.
  29. Disconnect the canister purge hose from the throttle body.
  30. Disconnect the fuel tube spring lock couplings.
  31. Remove the wiring harness retaining clip.
  32. Disconnect the evaporative emissions (EVAP) canister vacuum tube.
  33. Disconnect the connector for the engine control wiring harness.
  34. Disconnect the brake booster vacuum hose and the ground strap.
  35. Disconnect the electrical connector for the powertrain control module (PCM).
  36. Disconnect the PCM ground strap.
  37. Remove the accelerator cable snow shield.
  38. Disconnect the accelerator and speed control cables from the throttle body and routing bracket.
  39. Disconnect the heater hoses.
  40. Use the fan pulley holding tool (303-239) and the fan clutch nut wrench (303-240) to remove the fan blade and fan clutch as an assembly.
  41. Disconnect the electrical connector for the mass air flow (MAF) sensor.
  42. Disconnect the vacuum tube from the vacuum reservoir.
  43. Disconnect the electrical connectors for the right and left heated oxygen sensors (HO2S).
  44. Remove the left-hand motor mount nuts.
  45. Attach the lifting eyes (303-D030) to the threaded holes in the cylinder head.
  46. Support the engine using the spreader bar (303-D089) and a floor crane.
  47. Support the transmission with an appropriate floor jack.
  48. Remove the engine from the vehicle.

To Install:

NOTE: Make sure to route the transmission wiring harness and electrical connectors close to their connected locations.

  1. Place the engine in the vehicle.
  2. Remove the floor jack supporting the transmission.
  3. Remove the floor crane, the spreader bar (303-D089), and the lifting eyes (303-D030).
  4. As an assembly, install the fan blade and fan clutch using the fan pulley holding tool (303-239) and the fan clutch nut wrench (303-240). Torque to 41 ft-lb (55 Nm).
  5. Place the fan shroud onto the fan blade.
  6. Install the radiator and the retaining bolts. Torque to 62 in-lb (7 Nm).
  7. Install the fan shroud. Torque to 62 in-lb (7 Nm).
  8. Safely raise and support the vehicle.
  9. On vehicles with manual transmission ONLY: Install the transmission-to-engine bolts. Torque to 44 ft-lb (60 Nm).
  10. On vehicles with automatic transmission ONLY: Install two M20 x 1.6 in (40 mm) transmission mounting bolts and four M10 x 2 in (50 mm) transmission mounting bolts. Torque to 35 ft-lb (48 Nm).
  11. Install the transmission cooler tubes into the clips on the bottom of the radiator.
  12. Install the torque converter nuts. Torque to 26 ft-lb (35 Nm).
  13. Install the transmission-to-oil pan bolts. Torque to 35 ft-lb (48 Nm).
  14. Install the lower radiator hose.
  15. If present, install the engine damper bolt. Torque to 35 ft-lb (48 Nm).
  16. Connect the right and left exhaust pipes to the exhaust manifolds. Torque to 30 ft-lb (40 Nm).
  17. Install the starter motor.
  18. Connect the electrical connectors for the transmission and the wiring harness retainers.
  19. Connect the electrical connector for the catalyst monitor and attach the connector to the bracket.
  20. Install the lower radiator air deflector. Torque to 11 ft-lb (15 Nm).

    NOTE: It may be easier to access the nuts and bolts if you partially lower the vehicle and work through the opening of the right wheel well.

  21. Install the right-hand motor mount nuts and the transmission cooler tube bracket bolt. Torque top nuts to 80 ft-lb (109 Nm). Torque the side bolt to 15 ft-lb (20 Nm).
  22. Lower the vehicle.
  23. Install the left-hand motor mount nuts. Torque to 80 ft-lb (109 Nm).
  24. Connect the heater hoses then connect the vacuum tube to the vacuum reservoir.
  25. Connect the electrical connector for the MAF sensor.
  26. Connect the A/C manifold and tube to the suction accumulator/drier.
  27. Connect the peanut fitting on the A/C discharge tube. Torque to 89 in-lb (10 Nm).
  28. Connect the canister purge hose to the throttle body.
  29. Connect the B+ wiring lead to the generator. Torque to 8 ft-lb (11 Nm).
  30. Connect the A/C compressor clutch and high pressure cut-off switch electrical connectors.
  31. Use the Teflon ® seal replacer set (211-D027) to install a new seal on the power steering pressure tube.
  32. Connect the power steering pressure and return tubes. Torque to 35 ft-lb (48 Nm).
  33. Install the wiring harness retaining clip.
  34. Connect the accelerator and speed control cables.
  35. Install the accelerator cable snow shield.
  36. If present, connect the transmission cooler tubes. Torque to 15 ft-lb (20 Nm).
  37. Connect the PCM ground strap. Torque to 89 in-lb (10 Nm).
  38. Connect the electrical connector for the PCM, correctly position the harness support, and install the nut. Torque the PCM connector bolt to 44 in-lb (5 Nm).
  39. Connect the brake booster vacuum hose.
  40. Connect the engine control wiring harness connector. Torque to 53 in-lb (6 Nm).
  41. Connect the evaporative emissions (EVAP) canister vacuum tube then connect the electrical connectors for the right and left HO2S.
  42. Connect the fuel tube spring lock couplings.
  43. Install the upper radiator hose.
  44. Connect the ground strap. Torque to 89 in-lb (10 Nm).
  45. Install the air cleaner outlet pipe.
  46. Connect the coolant recovery hose and the negative battery cable.
  47. Install the hood.
  48. Fill the crankcase with clean engine oil.
  49. Fill and bleed the engine cooling system.
  50. Fill and purge the power steering system.
  51. Charge the A/C system.
  52. Check the level of transmission fluid.

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