Engine Removal and Installation

REMOVAL PROCEDURE





1. Disconnect the battery negative cable.
2. Remove the hood.
3. If the vehicle is equipped with a manual transmission, remove the shift lever.
4. Raise the vehicle.
5. Disconnect the exhaust pipe from the exhaust manifold.
6. Disconnect the catalytic converter from the exhaust pipe.
7. Remove the oil filter drain deflector from the brace rod, if equipped.





8. Remove the brace rods from the engine and the transmission, manual transmission only.
9. Remove the starter motor.
10. In order to gain access to the top transmission bolts, lower the rear of the transmission after removing the crossmember. The engine and transmission will pivot on the engine mounts.
11. Remove the transmission.
12. Disconnect the oxygen sensor electrical connector





13. Remove the right fender wheelhouse extension.
14. Remove the generator rear brace using the following procedure:
14.1. Remove the bolt from the rear of the generator.
14.2. Remove two nuts holding the brace to the engine.
14.3. Remove the brace from the engine.





15. Remove the bolt holding the battery negative cable to the engine.
16. Remove the bolt holding the ground wires to the engine.
17. Disconnect the following electrical connectors from the left side of the engine:
^ Engine oil pressure gauge sensor.
^ Camshaft position (CMP) sensor.
^ Ignition control module (ICM).
^ EVAP purge canister solenoid valve.
^ Crankshaft position (CKP) sensor.
^ Knock (KS) sensor.





18. Remove the nut holding the engine wiring harness bracket to the rear lower intake stud.
19. Remove the bolt holding the engine wiring harness to the intake manifold.
20. Lower the vehicle.
21. Remove the air intake duct.
22. Remove the radiator.
23. Remove the drive belt.

IMPORTANT: Do not evacuate the A/C system.

24. Remove the air conditioning compressor, if equipped, and set it aside.
25. Remove the power steering pump and set it aside.
26. Disconnect both heater hoses from the heater core.





27. Disconnect the vacuum brake booster hose.

CAUTION: IN ORDER TO AVOID POSSIBLE INJURY OR VEHICLE DAMAGE, ALWAYS REPLACE THE ACCELERATOR CONTROL CABLE WITH A NEW CABLE WHENEVER YOU REMOVE THE ENGINE FROM THE VEHICLE.
IN ORDER TO AVOID CRUISE CONTROL CABLE DAMAGE, POSITION THE CABLE OUT OF THE WAY WHILE YOU REMOVE OR INSTALL THE ENGINE. DO NOT PRY OR LEAN AGAINST THE CRUISE CONTROL CABLE AND DO NOT KINK THE CABLE. YOU MUST REPLACE A DAMAGED CABLE.

28. Disconnect the accelerator control cable and the cruise control cable, if equipped.





29. Disconnect the battery positive cable from the battery.
30. Disconnect the 12 volt supply from the mega fuse. Leave the battery positive cable on the engine.
31. Disconnect the following electrical connectors from the top of the engine:
^ Fuel injector harness
^ Engine coolant temperature (ECT) sensor
^ Idle air control (IAC) motor
^ Manifold absolute pressure (MAP) sensor
^ Throttle position (TP) sensor

32. Disconnect the engine block heater, if equipped.





33. Disconnect the electrical connection from the generator.
34. Disconnect the generator output wire from the generator
35. Move the engine wiring harnesses aside.
36. Disconnect the fuel pipes from the fuel rail.





37. Install a suitable engine lifting device to the engine lift brackets.





38. Remove the left side engine mount through-bolt.





39. Remove the right side engine mount through-bolt.
40. Remove the engine from the vehicle.

INSTALLATION PROCEDURE





1. Install the engine to the vehicle.
2. Install the right side engine mount through-bolt.
3. Install the left side engine mount through-bolt.
4. Remove the engine lifting device from the engine lift brackets.
5. Connect the fuel pipes to the fuel rail.





6. Position the engine wiring harnesses.

NOTICE: Refer to Fastener Notice in Service Precautions.

7. Connect the generator output wire to the generator.
^ Tighten the nut to 17 Nm (12 ft. lbs.).

8. Connect the generator electrical connector.
9. Connect the engine block heater, if equipped.





10. Connect the following electrical connectors to the top of the engine:
^ Fuel injector harness
^ Engine coolant temperature (ECT) sensor
^ Idle air control (IAC) motor
^ Manifold absolute pressure (MAP) sensor
^ Throttle position (TP) sensor

11. Connect the 12 volt supply to the mega fuse.
12. Connect the battery positive cable to the battery.

CAUTION: IN ORDER TO AVOID POSSIBLE INJURY OR VEHICLE DAMAGE, ALWAYS REPLACE THE ACCELERATOR CONTROL CABLE WITH A NEW CABLE WHENEVER YOU REMOVE THE ENGINE FROM THE VEHICLE.
IN ORDER TO AVOID CRUISE CONTROL CABLE DAMAGE, POSITION THE CABLE OUT OF THE WAY WHILE YOU REMOVE OR INSTALL THE ENGINE. DO NOT PRY OR LEAN AGAINST THE CRUISE CONTROL CABLE AND DO NOT KINK THE CABLE. YOU MUST REPLACE A DAMAGED CABLE.

13. Install a NEW accelerator control cable.
14. Connect the cruise control cable to the throttle body, if equipped.
15. Install both heater hoses to the heater core.
16. Install the power steering pump.
17. Install the air conditioning compressor, if equipped.
18. Install the drive belt.
19. Install the radiator
20. Install the air intake duct.





21. Connect the vacuum brake booster hose.





22. Raise the vehicle.
23. Install the bolt holding the engine wiring harness to the intake manifold
^ Tighten the engine wiring harness bolt to 12 Nm (106 inch lbs.).

24. Install the nut holding the engine wiring harness bracket to the rear lower intake stud.
^ Tighten the engine wiring harness bracket nut to 30 Nm (22 ft. lbs.).





25. Connect the following electrical connectors to the right side of the engine:
^ Engine oil pressure sensor
^ Camshaft position (CMP) sensor
^ Ignition control module (ICM)
^ EVAP purge canister solenoid valve
^ Crankshaft position (CKP) sensor
^ Knock (KS) sensor
26. Install the bolt and the ground wires to the engine.
^ Tighten the ground wire bolt to 35 Nm (26 ft. lbs.).

27. Install the bolt and the battery negative cable to the engine.
^ Tighten the battery negative cable bolt to 35 Nm (26 ft. lbs.).





28. Install the generator brace using the following procedure.
28.1. Install the brace to the engine.
28.2. Install the two nuts holding the brace to the engine.
28.3. Install the bolt to the rear of the generator.
^ Tighten the generator rear brace nuts and bolt to 25 Nm (18 ft. lbs.).

29. Install the right fender wheelhouse extension.
30. Connect the oxygen sensor electrical connector.
31. Install the transmission.
32. Install the starter motor.





33. Install the brace rods to the transmission and the engine, manual transmission only.
^ Tighten the brace bolts to 50 Nm (37 ft. lbs.).





34. Install the oil filter drain deflector on the brace rod, if equipped.
35. Connect the catalytic converter to the exhaust pipe.
36. Connect the exhaust pipe to the exhaust manifold.
37. Lower the vehicle.
38. Install the manual transmission shift lever, if removed.
39. Install the hood.
40. Connect the battery negative cable.
41. Fill the crankcase with oil.
42. Fill the cooling system with coolant.
43. Operate and test the engine.