Engine Removal
^ Tools Required- J 41602 Body Protection Hoist Adapter Set
- J 41617 Twin Post Hoist Frame Assembly Support Bar
- J 41427 Universal Lift Bracket
- Or equivalent
CAUTION:
^ This procedure must performed on a side lift hoist or a twin post hoist. The engine and mounting frame will be removed out of the bottom of the vehicle, therefore, a single post hoist can not be used to perform this procedure.
^ Failure to flush out the oil cooling system or the engine cooling system may result in premature failure of the replacement engine.
^ If the engine is damaged internally and a new engine is installed, make sure that all foreign material is completely flushed out of the cooling system.
^ The oil cooler system should also be flushed out (if equipped).
1. Remove the battery.
2. Remove the engine cover.
3. Remove the air filter assembly.
4. Disconnect the throttle cable from the throttle body bracket.
5. Disconnect the cruise control cable from the throttle body bracket (if equipped).
6. Disconnect the cruise control stepper motor electrical connection (if equipped).
7. Disconnect the air conditioning lines at the accumulator and the condenser (if equipped).
8. Evacuate the air conditioning system.
9. Remove the radiator.
10. Remove the power steering reservoir and drain the fluid.
11. Disconnect the lines from the hydro boost unit.
12. Disconnect the master cylinder from the hydro boost unit. Tie the master cylinder to the oil fill tube.
13. Disconnect the steering shaft from the steering gear.
14. Disconnect the heater hoses from the engine.
15. Disconnect the vacuum line at the vacuum tank.
16. Disconnect the fuse box and the wiring harness from the bulkhead connector and all related electrical connectors.
17. Lay the harness on the engine.
18. Raise the vehicle.
19. Drain the crankcase.
20. Remove the rear propeller shaft.
21. Remove the starter and the starter opening shield.
22. Remove the torque converter bolts through the starter motor opening.
23. Disconnect the shift linkage from the transmission.
24. Disconnect the exhaust system at the main flange behind the catalytic converter.
25. Remove the park brake bracket from the frame.
26. Disconnect the rear brake line from the BMPV.
27. Remove the front bumper.
28. Disconnect the power steering cooler from the front air deflector.
29. Disconnect the SIR sensor connector.
30. Disconnect the wheel housing splash shields from the chassis to the frame.
31. Disconnect the rear air conditioning lines at the rear crossmember (if equipped).
32. Leave the air conditioning lines attached to the powertrain assembly.
33. Disconnect the fuel lines at the fuel filter.
34. Pull the fuel lines through the crossmember (forward). Lay the fuel lines on the transmission.
35. Disconnect the fuel tank electrical connector.
36. Disconnect the transfer case vent hose.
37. Make sure all the connections are disconnected between the chassis and the frame.
WARNING: To help avoid personal injury when vehicle is on a hoist, provide additional support for the opposite arid from which components are being removed. The additional support will reduce the possibility of the vehicle falling off the hoist. When removing major components of the vehicle while the vehicle is on a hoist, the vehicle frame should be chained to the hoist pads at the same end as Me removed components to prevent tip-off. Failure to follow these precautionary measures could result in vehicle damage, serious personal injury or death.
38. Attach the side lift hoist using the following method:
a. Install the J 41602 to the pinch weld area on both sides of the vehicle.
b. Lower the vehicle.
c. Position the front hoist arms under the body protection hoist adapter set.
d. Make sure the rear of the vehicle is slightly higher than the front.
e. Support the rear crossmember with suitable stands.
f. Remove the frame bolts.
g. Raise the hoist in order to separate the body from the frame assembly.
h. Install support stands under the rear axle.
39. Attach the twin post hoist using the following method:
a. Install the J 41602 to the pinch weld area on both sides of the vehicle.
b. Install the stands under the body protection hoist adapter set and the rear of the vehicle in order to support the vehicle.
c. Lower the front post of the hoist.
d. Install the J 41617 to the hoist.
e. Raise the front post of the hoist with the tool attached.
f. Remove the frame bolts.
g. Lower the power/rain/frame assembly.
40. Install the J 41427 using the following procedure:
a. Disconnect the spark plug wires.
b. Remove the distributor cap.
c. Remove the two right rear lower intake manifold bolts.
d. Install the J 41427 marked RIGHT REAR.
e. Install the retaining bolts.
- Tighten the retaining bolts to 15 Nm (11 ft. lbs.).
f. Remove the air conditioning compressor and the accessory drive bracket.
g. Disconnect the EGR tube from the intake manifold.
h. Remove the two left front lower intake manifold bolts.
i. Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of the engine.
j. Install the retaining bolts.
- Tighten the retaining bolts to 15 Nm (11 ft. lbs.).
41. Remove the engine mount through bolts.
42. Disconnect the fuel line bracket from the rear of the left cylinder head.
43. Disconnect the fuel lines from the fuel rail.
44. Disconnect the electrical harness at the transmission connections and at all emission sensors.
45. Disconnect the transfer case to the engine block support brace.
46. Slightly raise the engine. Support the transmission with suitable floor stands and a block of wood. Do not support the transmission under the oil pan.
47. Remove the exhaust "Y" pipe from the exhaust manifolds.
48. Disconnect the engine from the transmission.
49. Remove the engine from the frame.