ENGINE REPAIR

Engine Assembly

REMOVAL & INSTALLATION

2.3L Engine

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.
4. Drain the engine oil.
5. Properly discharge the A/C system.
6. Remove or disconnect the following:
   • Both battery cables
   • Intake Air Temperature (IAT) sensor
   • Air cleaner outlet tube
   • Drive belt
   • Accelerator control splash shield
   • Upper and lower radiator hoses
   • Fan guard/shroud
   • Radiator overflow hoses
   • Radiator
   • Engine Coolant Temperature (ECT) sensor
   • Alternator
   • Upper and lower heater hoses
   • Ignition wires from the coils
   • Ignition coil wiring
   • Radio ignition interference capacitor wiring
   • Water pump inlet tube
   • Alternator mounting bracket
   • Acceleratgor cable
   • Both engine compartment wiring harness, 42 pin and 104 pin connectors
   • Exhaust Gas Recirculation (EGR) pressure sensor
   • Evaporative (EVAP) emissions purge hose
   • A/C hoses
   • A/C compressor manifold and tube
   • Power steering pump bracket
   • Heated Oxygen (HO2S) sensor
   • Catalytic converter from the exhaust manifold
   • Fuel supply and return hoses from the fuel injection supply manifold
   • 3 transmission connector leads
   • Ground cable from the left side of the engine
   • Starter
   • Torque converter-to-flywheel bolts, if equipped
   • Engine-to-transmission from the rear support brackets
   • Lower engine-to-transmission bolts and spacers, if equipped
7. Support the transmission with a floor jack.
8. Using an engine crane or hoist, lift the engine out of the vehicle. Be sure to lift the engine slowly and check often that nothing (such as wires, hoses, etc.) will cause the engine to hang up on the vehicle.

   To install:

   NOTE: Lightly oil all bolts and stud threads, except those specifying special sealant, prior to installation.

9. Using the hoist or engine crane, slowly and carefully position the engine in the vehicle. Make sure the exhaust manifolds are properly aligned with the exhaust pipes.
10. Align the engine to the transmission and install 2 engine-to-transmission bolts.

    NOTE: Seat the left-hand side, front engine support insulator locating pin prior to the right-hand side, front engine support insulator.

11. Lower the engine onto the front engine support insulators.
12. Detach the engine crane or hoist from the engine.
13. Remove the floor jack from beneath the transmission fluid pan.
14. Install or connect the following:
    • Torque the engine-to-transmission bolts to 38 ft. lbs. (51 Nm)
    • Torque converter-to-transmission bolts. Torque the bolts to 39 ft lbs. (52 Nm).
    • Starter. Torque the bolts to 20 ft. lbs. (27 Nm).
    • Ground cable to the left side of the engine
    • Transmission lead to fuel charging wiring
    • Fuel supply and return lines
    • Catalytic converter to the exhaust manifold. Torque the bolts to 25 ft. lbs. (34 Nm).
    • Cable brackets
    • HO2S sensor
    • Starter electrical connectors
    • Top engine-to-transmission bolts. Torque the bolts to 38 ft. lbs. (51 Nm).
    • 42 and 104 pin engine harness connectors
    • EVAP purge hose
    • EGR pressure sensor
    • Dash panel ground cable
    • Brake booster vacuum hose
    • Accelerator cable bracket. Torque the bolts to 21 ft. lbs. 28 Nm).
    • Accelerator cable to the throttle body
    • Upper and lower heater hoses
    • Alternator mounting bracket. Torque the bolts to 40 ft. lbs. (54 Nm).
    • Alternator. Torque the bolts to 40 ft. lbs. (54 Nm).
    • Ignition coil electrical connectors
    • Spark plug wires to the ignition coils
    • Drive belt. Torque the fan clutch bolts to 16 ft. lbs. (23 Nm).
    • ECT sensor
    • Alternator electrical connectors
    • Fan shroud on the fan blade, if equipped with A/C
    • Radiator and install the fan shroud/guard
    • Radiator overflow hose
    • Upper and lower cooling hoses
    • A/C compressor and recharge the system
    • Air cleaner outlet tube
    • Accelerator control splash shield
    • IAT sensor
    • Both battery cables
15. Fill the cooling system.
16. Fill the engine with clean oil.
17. Run the engine and check for leaks and proper operation.
18. Check and adjust the front end alignment.

2.5L, 3.0L and 4.0L Engines

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.
4. Drain the engine oil.
5. Properly discharge the A/C system.
6. Remove or disconnect the following:
   • Both battery cables
   • Mass Air Flow (MAF) sensor
   • Air cleaner outlet tube
   • Drive belt
   • Accelerator control splash shield
   • Upper and lower radiator hoses
   • Fan guard/shroud
   • Radiator overflow tube
   • Radiator
   • Transmission cooler lines, if equipped
   • Heater hoses
   • Alternator electrical connectors
   • Vacuum reservoir connection
   • Throttle body heater hose
   • A/C cycling switch
   • Powertrain Control Module (PCM) connector
   • Ground wire from the PCM
   • Power steering cut-out switch
   • Peanut fitting from the A/C condenser core
   • A/C high pressure cut-out switch
   • A/C manifold hose
   • Accelerator and speed control cables
   • Brake booster vacuum hose and tube from the intake manifold
   • Vacuum reservoir line
   • Fuel lines
   • Power steering pressure and return hoses
   • Block heater, if equipped
   • Engine ground cable
   • Automatic transmission harness connectors, if equipped
   • Heated Oxygen (HO2S) sensor, if equipped
   • Starter
   • Catalytic converter
   • Torque converter bolts, if equipped and properly support the transmission
   • Differential pressure feedback sensor and support the engine with a floor crane
   • Exhaust Gas Recirculation (EGR) transducer
   • Upper transmission-to-engine bolts
   • Engine from the vehicle
   • Clutch/ flywheel, if equipped

   To install:

7. Install or connect the following:
   • Flywheel. Torque the bolts to 64 ft. lbs. (87 Nm).
   • Engine. Torque the mounting bolts to 85 ft. lbs. (115 Nm).
   • HO2S sensor
   • Upper transmission-to-engine bolts. Torque the bolts to 38 ft. lbs. (51 Nm).
   • EGR transducer and remove the floor jack from the transmission
   • Torque converter-to-engine bolts. Torque the bolts to 38 ft. lbs. (51 Nm).
   • Catalytic converter
   • Transmission wiring harness connectors
   • Engine ground cable. Torque the bolt to 106 inch lbs. (12 Nm).
   • Block heater, if equipped
   • A/C high pressure cut out switch
   • A/C manifold to the evaporator core
   • Power steering cut-out switch
   • Power steering pressure and return lines
   • Engine sensor control wiring harness to the A/C compressor
   • Fuel lines
   • 42 pin connector
   • Vacuum reservoir vacuum line
   • Brake booster vacuum hose and tube
   • Accelerator cable
   • Ground strap. Torque the bolt to 106 inch lbs. (12 Nm).
   • A/C manifold hose
   • PCM ground strap. Torque the bolt to 106 inch lbs. (12 Nm).
   • PCM wire harness bracket bolt. Torque the bolt to 61 inch lbs. (7 Nm).
   • A/C low pressure cut-out switch
   • Throttle body heater hose
   • Fan clutch and water pump pulley. Torque the bolt 17 ft. lbs. (23 Nm).
   • Drive belt
   • Alternator electrical connectors
   • Inlet and outlet heater hoses
   • Fuel charging wiring
   • Radiator and fan shroud
   • Transmission cooler lines, if equipped
   • Upper, lower and overflow hoses to the radiator
   • Accelerator control splash shield. Torque the bolts to 89 inch lbs. 10 Nm).
   • Drive belt
   • Air cleaner outlet tube
   • MAF sensor
   • Both battery cables
8. Recharge the A/C system.
9. Fill the cooling system.
10. Fill the engine with clean oil.
11. Run the engine and check for leaks and proper operation.
12. Check and adjust the front end alignment.