Engine Assembly

Removal & Installation

To Remove:

CAUTION
Do not use the fuel supply manifold to pry on. Damage may occur to the supply manifold. Care must be taken when working around the fuel supply manifold.

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 spring lock couplings.
7. BEFORE removing the hood, mark the hinge locations for installation reference.
8. Disconnect the MAF.
9. Remove the fan blade and the air cleaner housing cover.
10. Remove the radiator.
11. Disconnect the accelerator and speed control cables.
12. If the vehicle has A/C, disconnect the A/C field coil electrical connector and the high pressure switch electrical connector. Next, remove the bolt and place the A/C hoses aside.
13. Remove the accessory drive belt.
14. Disconnect the high-pressure hose from the lower power steering pump fitting.
15. Disconnect the power steering return hose from the power steering fluid reservoir.
16. Remove the accessory bracket bolts, the bracket, and the A/C compressor (if present). Remove the power steering pump and the power steering reservoir as an assembly.
17. Disconnect the generator.
18. Disconnect the wiring harness retainer.
19. Loosen the bolt and disconnect the engine wiring harness.
20. Remove the engine wiring harness retainer nut.
21. Disconnect the PCM.
22. Remove the retainer from the PCM ground wire and place wiring harness to the side.
23. Remove the retainer from the engine ground wire.
24. Disconnect the brake booster vacuum hose.
25. Disconnect the vapor hose and pin-type retainer.
26. Remove the crankcase breather hose and disconnect the two vacuum hoses.

    NOTE: Heater hose will be removed with the engine, so just disconnect the heater hose for now.

27. On vehicles with automatic transmission: Remove the transmission level indicator tube nut.
28. Remove the starter motor.
29. Remove the bolt and the engine wiring harness bracket. Disconnect the oil pressure sensor.
30. On vehicles with automatic transmission: Disconnect the transmission control and input shaft electrical connectors. Remove the wiring harness pin-type retainer. Next, disconnect the output shaft speed (OSS) sensor and digital transmission range (TR) sensor. Remove the bolt and put the transmission cooling tube bracket aside. Remove the four torque converter nuts.
31. On vehicles with manual transmission: Disconnect the reversing lamp switch. Next, disconnect the OSS sensor and detach the heated oxygen sensor from the bracket.
32. Drain the engine oil, install the oil drain plug, and remove the oil filter.
33. Disconnect the heated oxygen sensor on the right-hand side, then on the left-hand side.
34. Remove the Y-pipe-to-catalytic-converter nuts, bolts, and gasket.
35. Remove the nuts and the exhaust pipe.
36. Disconnect the wiring harness electrical connector located on the frame.
37. Release the transmission/transfer case portion of the wiring harness from any routing clips or pin-type retainers.
38. Route the transmission/transfer case portion of the wiring harness to the top of the engine.
39. If vehicle has A/C, remove the A/C tube bracket nut.
40. Remove the eight transmission bolts.
41. Remove the engine insulator nuts on the right-hand side, then the left-hand side.

    NOTE: The lifting eyes should be installed on the exhaust manifold studs for number three and number four cylinders.

42. Install the lifting bracket on the left side, then on the right side.
43. Install the spreader bar to the lifting eyes, then position a floor jack under the bell housing of the transmission.
44. Attach a floor crane to the spreader bar and remove the engine.

To Install:

CAUTION
Do not use the fuel supply manifold to pry on. Damage may occur to the supply manifold. Care must be taken when working around the fuel supply manifold.

1. Install the engine then remove the floor crane and the spreader bar.
2. Install the engine insulator nuts, doing the left-hand side first, then the right-hand side.
   • Torque to 81 ft-lb (110 Nm).
3. Install the eight transmission-to-engine bolts.
   • Torque to 35 ft-lb (47 Nm).
4. If vehicle has A/C, position the A/C tube bracket and install the nut.
5. Route the transmission/transfer case portion of the wiring harness down to the transmission.
6. Attach the transmission /transfer case portion of the wiring harness to any routing clips or pin-type retainers.
7. Connect the wiring harness located on the frame.
8. Position the Y-pipe and install the gasket, the bolts, and the nuts.
   • Torque to 30 ft-lb (40 Nm).
9. Connect the heated oxygen sensor on the left-hand side then the right-hand side.
10. Install a new engine oil filter.
11. On vehicles with manual transmission: Connect the output shaft speed (OSS) sensor then attach the heated oxygen sensor to the bracket. Connect the reversing lamp switch.
12. On vehicles with automatic transmission: Install the four torque converter nuts and Torque to 35 ft-lb (47 Nm). Next position the transmission cooling tube bracket and install the bolt. Connect the output shaft speed (OSS) sensor and digital transmission range (TR) sensor. Connect the transmission control and input shaft electrical connectors. Install the wiring harness pin-type retainer. Position the transmission level indicator tube and install the nut.
13. Install the starter motor.
14.  Connect the heater hose.
15. Install the crankcase breather hose and connect the two vacuum hoses.
16. Install the vapor hose and attach the pin-type retainer.
17. Connect the vapor hose.
18. Connect the brake booster vacuum hose.
19. Position the engine ground wire and install the retainer.
20. Position the PCM electrical ground wire and install the retainer.
21. Connect the PCM and tighten the bolt.
22. Position the engine wiring harness and install the retainer nut.
23. Connect the engine wiring harness and tighten the bolt.
24. Install the engine wiring harness bracket and bolt and connect the oil pressure sensor.
25. Position the wiring harness and install the bolt.
26. Connect the generator wiring.
27. Position the accessory bracket, the A/C compressor (if present), and the power steering pump and power steering fluid reservoir as an assembly and install the accessory bracket bolts.
28. Connect the power steering return hose to the power steering fluid reservoir.
29. Connect the power steering high-pressure hose to the lower power steering pump fitting.
30. If equipped with A/C, position the A/C compressor manifold tube and install the bolt. Next, connect the A/C high-pressure switch and the field coil electrical connector.
31. Install the accessory drive belt.
32. Connect the accelerator and speed control cables.

    NOTE: Do not fill the cooling system at this time. Install the radiator.

33. Install the air cleaner housing cover.
34. Connect the MAF sensor.
35. Install the fan blade then install the hood.
36. Connect the spring lock couplings, then connect the battery ground cable.
37. Refill engine oil.
38. Fill the engine cooling system, then the power steering system.
39. If vehicle has A/C, recharge the A/C system.
40. Refill cooling system.
41. Install hood.