Engine: Service and Repair

REMOVAL

NOTE: The engine assembly can be removed through the front of the engine compartment without the transmission attached.

1. Open the hood and disconnect the battery negative cable.
2. Remove the front grille and inside engine cover.
3. Remove the air cleaner tube and the air cleaner assembly.
4. Disconnect and remove the air conditioner condenser (if so equipped).
5. Position a drain pan under the engine oil pan and drain the engine oil.
6. Position a drain pan, disconnect and remove the power steering oil cooler.
7. Remove the front bumper cover.
8. Position a drain pan, disconnect and remove the transmission oil cooler.
9. Drain the radiator and remove the upper and lower radiator hoses.
10. Disconnect the transmission oil cooler lines from the radiator.
11. Disconnect the radiator fan shroud and position it over the fan.
12. Remove the radiator.
13. Remove the accessory drive belt.
14. Remove the right front air diverter flap.
15. Remove the hood and the center hood latch support.

Alternator:

16. Disconnect and remove the alternator.
17. Disconnect and remove the air conditioner compressor (if so equipped).
18. Remove the engine oil fill tube.
19. From inside the vehicle. remove the engine cover.
20. Remove the ice/snow shield.
21. At the power steering pump. remove the power steering supply and return hoses.

Power Steering Pump:

22. Remove the power steering pump and mounting bracket.
23. Remove the transmission oil dipstick tube and dipstick.
24. Remove the engine oil dipstick and tube.
25. Disconnect the exhaust system from the engine exhaust manifolds.
26. Disconnect and remove the starter motor.
27. Remove the converter to flexplate bolts through the starter motor opening in the converter housing.

Transmission Oil Cooler Line Bracket:

28. Remove the transmission oil cooler line bracket retaining bolt.
29. Remove the engine mount to frame bolts (left and right sides).
30. Remove the converter housing to engine bolts, except the upper bolts.
31. Remove the left motor mount from the engine.

Upper Torque Converter Housing Bolts:

32. Remove the upper converter housing bolts.
33. Disconnect the transmission and transfer case electrical connectors.
34. Disconnect the fuel supply and return lines at the engine fuel supply manifold.
35. Disconnect the throttle linkage and bracket and position aside.
36. Disconnect the upper and lower heater hoses.
37. Disconnect the engine vacuum lines from the vapor canister, lower intake manifold and the upper intake manifold vacuum tee.
38. Remove the spark plug wires from the ignition control module assembly and disconnect and remove the ignition control module assembly, with mounting bracket.
39. Disconnect the electrical connector from the throttle body throttle position sensor.
40. Remove the throttle body and upper intake manifold as an assembly.
41. Disconnect the engine wiring harness main connectors.
42. Install engine lifting brackets on the right front and left rear of the engine and remove the engine assembly from the vehicle.

INSTALLATION
1. Position the engine assembly in the vehicle and remove the engine lifting brackets.
2. Connect the engine wiring harness main connectors.

Upper Intake Manifold:

3. Install the throttle body and upper intake manifold and tighten bolts to 20-25 Nm (15-15 ft lb)
4. Install the ignition control module and connect the spark plug wires and the coil assembly wiring connector.
5. Connect the electrical connector for the throttle position sensor.
6. Connect the upper and lower heater hoses.
7. Connect the engine vacuum lines to the vapor canister, lower intake manifold and the upper intake manifold vacuum tee.
8. Connect the throttle linkage and bracket.
9. Connect the fuel supply and return lines at the engine fuel supply manifold.
10. Install the left motor mount.
11. Install the converter housing to engine bolts. Connect the transmission and transfer case electrical connectors.
12. Install the engine mount to frame bolts (left and right sides).
13. Install the transmission oil cooler line bracket retaining bolt.
14. Through the starter motor opening in the converter housing, install the converter to flexplate bolts.
15. Install the starter motor and connect the starter motor wires. Connect the exhaust system to the engine exhaust manifolds.
16. Install the transmission oil dipstick tube and dipstick.
17. Install the engine oil dipstick and tube.
18. Install the power steering pump and mounting bracket.
19. Install the power steering supply and return hoses at the power steering pump.
20. Install the ice/snow shield.
21. Install the engine oil fill tube.
22. From inside the vehicle. install the engine cover.
23. Install and connect the air conditioner compressor (if so equipped).
24. Install and connect the alternator.
25. Install the hood and center hood latch support.
26. Install the right front air diverter flap.

Drive Belt Routing:

27. Install and tension the accessory drive belt.
28. Install the radiator.
29. Install the radiator fan shroud.
30. Connect the transmission oil cooler lines at the radiator.
31. Install the upper and lower radiator hoses, fill and bleed the cooling system.
32. Install the transmission oil cooler.
33. Install the front bumper cover.
34. Install and connect the power steering oil cooler.
35. Refill the engine with the recommended quantity and quality of engine oil.
36. Install and connect the air conditioner condenser (if so equipped).
37. Install the air cleaner assembly and air tube.
38. Install the front grille and inside engine cover.
39. Connect the battery negative cable.

NOTE: On vehicles equipped with EEC. when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.

WARNING: Do not operate engine with hood open until fan has been first checked for possible cracks and separation.