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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.
  4. Drain the engine oil.
  5. Properly discharge the A/C system and remove radiator hoses.
  6. Label the hood alignment for reinstallation.
  7. Remove the hood.
  8. Remove the upper intake manifold.
  9. Remove the drive belt.

    NOTE: The fan clutch has left-hand threads.

  10. Remove the fan clutch and blade as an assembly.
  11. Remove the fan shroud.
  12. Remove the radiator.
  13. Disconnect the heater hoses.
  14. Recover the A/C system.
  15. Disconnect the A/C manifold and tube and remove the nut.
  16. Disconnect the A/C compressor wiring.
  17. Remove nuts and detach the fuel tube bracket and the wiring harness bracket.
  18. Remove the stud bolts.
  19. Remove the A/C compressor and its mounting bracket.
  20. Remove the nut from the ground cable.
  21. Disconnect the fuel lines and the vacuum hose.
  22. Disconnect the PCM connector.
  23. Remove the nut from the PCM harness.
  24. Remove the stud bolt and the PCM group strap.
  25. Disconnect the generator wiring and both heated oxygen sensors.
  26. Disconnect the transmission harness connectors.
  27. Disconnect the vacuum hose from the vacuum reservoir.
  28. Disconnect the MAF.
  29. Remove the four nuts and disconnect the dual converter Y-pipe from both exhaust manifolds.
  30. Remove the starter motor.
  31. On vehicles with automatic transmission: For installation reference, be sure to mark one stud and the flexplate, then remove the torque converter nuts and the bolt.
  32. Remove the eight transmission-to-engine bolts.
  33. Install the lifting eyes and remove the four nuts.
  34. Support the transmission with a floor jack.
  35. Remove the engine from the vehicle.

To Install:

NOTE: In vehicles with automatic transmission, make sure the torque converter stud and flexplate marks made during removal are aligned.

  1. Place the engine in the vehicle and install the four nuts.
  2. Install the eight transmission-to-engine bolts.
  3. On vehicles with automatic transmission: Install the transmission cooler line bracket and bolt, then install the four torque converter nuts.
  4. Install the starter motor.
  5. Connect the dual converter Y-pipe and install the nuts.
  6. Install the heated oxygen sensors.
  7. Connect the MAF.
  8. Connect the vacuum hose.
  9. Connect the transmission wiring harness connectors.
  10. Connect the generator wiring harness.
  11. Install the PCM group strap.
  12. Install the PCM wiring bracket.
  13. Connect the engine control wiring harness to the PCM.
  14. Connect the fuel hoses.
  15. Install the ground cable.
  16. Connecting the wiring to the PCM.
  17. Position the A/C compressor and A/C compressor mounting bracket as an assembly and install the bolts.
  18. Install the stud bolts to the A/C compressor mounting bracket.
  19. Position the wiring harness bracket and the fuel hose bracket and install the nuts.
  20. Connect the A/C compressor electrical connector.
  21. Install the fuel tube bracket.
  22. Position the A/C suction/discharge tube and install the nut.
  23. Connect the A/C tube at the accumulator.
  24. Install the suction/discharge manifold on the A/C compressor.
  25. Connect the engine sensor control wiring to the A/C cut-out switch.
  26. Connect the heater hoses.
  27. Install the radiator and the fan shroud.

    NOTE: The fan clutch has left-hand threads. Using the special tool, install the fan clutch and blade.

  28. Install the accessory drive belt.
  29. Connect the upper radiator hose and the lower radiator hose to the radiator.
  30. Install the upper intake manifold.
  31. Install the hood.
  32. Fill the engine with clean engine oil.
  33. Connect the battery ground cable.
  34. Fill and bleed the engine cooling system.
  35. Charge the A/C system.
  36. Inspect the engine and cooling system for leaks.
  37. The starter motor MUST be removed to gain access to all the oil pan bolts. This step is only necessary if the oil pan was off during the engine removal. Once the engine has reached operating temperature, retighten the oil pan bolts working from the rear bolts to the front.
  38. Refill cooling system and engine oil.
  39. Properly recharge the A/C system.
  40. Install hood.

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