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 battery ground cable.
4. Recover the A/C system.
5. Drain the cooling system and the engine oil.
6. Label the hood alignment for reinstallation before removing the hood.
7. Remove the accelerator control snow shield and the air cleaner tube.
8. Remove the radiator hoses, the fan, and the shroud.
9. Disconnect the PCM.
10. Remove the retaining nut from the harness clamp.
11. Remove the ground stud for the PCM.
12. Disconnect the heater hoses at the bulkhead and at the engine then remove the assembly.
13. Disconnect the vacuum hoses and the hoses from the coolant reservoir.
14. Disconnect the A/C compressor clutch electrical connector and the mass airflow sensor electrical connector.
15. Disconnect the A/C compressor manifold then plug the lines and the compressor ports.
16. Disconnect the accelerator and speed control cables (if present).
17. Disconnect the power steering pressure switch and the power steering hose.
18. Disconnect the fuel supply hose, the 42-pin electrical connector, and the evaporative purge hose.
19. Disconnect the brake booster vacuum hose and the engine ground strap.
20. Disconnect the battery cables and the solenoid control wire at the starter motor.
21. Remove the starter wiring harness clamp bolt.
22. Move the RH splash shield out of the way.
23. Disconnect the generator electrical connections.
24. Detach alternator wiring pin-type retainer.
25. Disconnect the block heater electrical connector if one is present.
26. Disconnect the heated oxygen sensor electrical connector at the bell housing.
27. On vehicles with automatic transmission: Remove the bolt retaining the transmission cooling tubes to the engine then remove the bracket.
28. Remove the transmission dust shield and the exhaust manifold-to-front pipe nuts.
29. Disconnect the heated oxygen sensor at the rear of the transmission.
30. Remove the engine wiring harness anchor and the pin-type retainer.
31. Disconnect the oil pressure sensor.
32. Remove the engine oil filter.
33. On vehicles with automatic transmission: Disconnect the vehicle speed sensor, transmission range sensor, backup light switch, and the transmission electrical connectors. Next disconnect the pin-type retainers and position the transmission wiring harness forward toward the engine.
34. On vehicles with manual transmission: Disconnect the electrical connector on the crossmember and the speed sensor then disconnect the reverse lamp and the two wiring pin-type retainers.
35. Remove the oil filter adapter, the bolts, the starter motor, and the starter motor dust shield.
36. On vehicles with automatic transmission: Be sure to mark one stud and the flexplate for assembly reference, then remove the four torque converter nuts.
37. Be sure to leave two side bolts in until the engine is ready to be removed, then remove nine of the transmission-to-engine bolts.
38. On vehicles with automatic transmission: Remove the transmission fluid indicator and tube assembly.
39. Install engine lifting bracket.
40. Support the transmission with a floor jack.
41. Support the engine with a floor crane using a spreader bar.
42. Remove the two transmission-to-engine bolts on the side and the four engine support insulator nuts.
43. Remove the engine from the vehicle.

To Install:

1. Remove the engine from the stand by using a floor crane and spreader bar.
2. Place the engine in the vehicle. Ensure that index marks made during removal on the flexplate and torque converter stud are lined up.
3. Install the two transmission-to-engine bolts on the side.
4. Install the four engine support insulator nuts.
   • Torque to 75 ft-lb (102 Nm).
5. Remove the floor jack from the transmission, then remove the spreader bar and floor crane.
6. On vehicles with automatic transmission: Install the four torque converter nuts.
   • Torque to 26 ft-lb (35 Nm).
7. Next, install the transmission fluid indicator and tube assembly.
8. Raise the vehicle then install the nine remaining transmission-to-engine bolts.
   • Torque to 35 ft-lb (48 Nm).
9. Install the oil filter adapter.
   • Torque to 18 ft-lb (25 Nm).
10. Install the starter motor dust shield.
11. Install the starter motor.
12. Install the oil filter.
13. Connect the oil pressure sensor electrical connector.
14. On vehicles with automatic transmission: Connect the transmission wiring harness.
15. On vehicles with manual transmission: Connect the lamp electrical connection and install the pin-type retainers, then connect the speed sensor electrical connector and the electrical connector on the crossmember.
16. Connect the heated oxygen sensor at the rear of the transmission.
17. Connect the heated oxygen sensor at the bell housing.
18. Install the exhaust manifold-to-front pipe nuts.
    • Torque to 30 ft-lb (40 Nm).
19. Install the transmission dust shield.
20. On vehicles with automatic transmission: Install the bracket and the bolt retaining the transmission cooling tubes to the engine.
    • Torque to 21 ft-lb (28 Nm).
21. Install the engine wiring harness in its original position.
22. Connect the block heater.
23. Attach the alternator wiring pin-type retainer.
24. Connect the generator.
25. Position the splash shield and install the pushpins.
26. Lower the vehicle.
27. Install the starter wiring harness and bolt.
28. Connect the wiring to the solenoid.
29. Connect the brake booster vacuum hose and the engine ground strap.
30. Connect the 42-pin electrical connector and the evaporative purge hose.
31. Connect the fuel supply hose.
32. When installing a new nylon O-ring seal, connect the power steering high-pressure hose and the power steering pressure switch electrical connector.
33. Connect the accelerator and speed control cables (if present).
34. Remove the plugs and connect the A/C compressor manifold.
35. Connect the mass air flow sensor.
36. Connect the A/C compressor clutch electrical connector.
37. Connect the coolant reservoir-to-engine supply hose.
38. Connect the engine-to-coolant reservoir bypass hose.
39. Connect the vacuum hose to the vacuum reservoir.
40. Install the heater hoses.
41. Install the ground stud for the PCM.
42. Connect the PCM.
43. Install the lower radiator hose, the fan shroud, then the upper radiator hose.
44. Install the air cleaner tube.
45. Install the accelerator control snow shield.
46. Install the hood.
47. Fill the engine with clean engine oil.
48. Connect the battery ground cable.
49. Refill cooling system.
50. Refill engine oil.
51. Refill power steering system.
52. Evacuate and charge the A/C system.
53. Properly recharge the A/C system.
54. Install hood.