Removal and Installation
Removal1. Disconnect negative cable from battery.
2. Remove refrigerant from air conditioning system using a refrigerant recovery machine.
3. Remove right and left hood side panels.
4. Mark hood position at hinges and remove hood.
5. Remove engine compartment supports.
6. Drain cooling system.
7. Remove upper radiator crossmember.
8. Remove fan module electrical connector.
9. Remove fan module.
Air Intake Duct:
10. Remove air intake duct from air cleaner and throttle body.
11. Remove upper intake manifold.
12. Cover lower intake manifold openings with tape or other suitable covering.
13. Remove air conditioning lines at condenser.
14. Remove coolant hoses from radiator and engine.
15. Remove radiator and condenser as an assembly.
16. Remove coolant pressure bottle.
17. Perform fuel pressure release procedures and disconnect fuel line.
18. Remove heater hoses.
19. Remove heater tube attaching screws from engine bell housing.
20. Disconnect all electrical connectors and ground straps.
21. Remove accessory drive belts.
22. Remove air conditioning lines at compressor.
23. Remove right headlamp, module for easier access to compressor bolts.
24. Remove air conditioning compressor mounting bolts and disconnect compressor electrical connector.
25. Remove compressor bracket from engine.
26. Remove compressor through front opening of engine compartment.
27. Disconnect electrical connector from air conditioning pressure transducer.
A/C Lines And Filter/Drier - Removal/Installation:
28. Remove air conditioning lines and filter/dryer.
29. Remove generator.
30. Remove power steering pump mounting bolts and set pump aside.
31. Hoist vehicle.
32. Drain engine oil and remove oil filter.
33. Loosen and remove V-Band clamps at exhaust manifold to catalytic converter connection.
NOTE: Do not reuse V-Band clamps.
34. Remove bolts at converter pipe support hangers. Lower exhaust enough for engine removal. Support exhaust system with wire or equivalent.
35. Disconnect starter wiring and remove starter.
36. Remove engine bell housing inspection cover.
37. Remove bolts holding drive plate to flex plate.
38. Remove the lower engine bell housing to block bolts.
39. Disconnect crankshaft position sensor electrical connector and remove sensor from engine bell housing.
40. Loosen right and left lower engine mount to crossmember nuts, but do not remove.
41. Lower vehicle.
42. Attach lifting hoist to the front and rear of engine.
NOTE: It is recommended that an adjustable load leveling fixture be used for removing and installing engine.
43. Lift engine enough to support weight of engine only.
44. Remove engine mount brackets to block bolts. Leave mount brackets and isolators attached to crossmember.
45. Remove upper engine bell housing to block bolts.
CAUTION: The engine bell housing must be kept at its designed driveline angle to prevent propeller shaft bushing damage.
46. Hoist engine from engine compartment.
Installation
1. If removed, install right and left engine mount isolators with brackets to crossmember, but do not tighten.
2. Attach hoist and lower engine into engine compartment.
3. Install bolts attaching engine bell housing to cylinder block. Tighten bolts to 102 Nm (75 ft. lbs.).
4. Align right and left engine mount brackets to engine block and torque bolts to 60 Nm (45 ft. lbs.).
5. Remove engine hoist and holding fixture.
6. Hoist vehicle.
7. Tighten engine mount right and left isolator to crossmember nuts. Tighten nuts to 101 Nm (75 ft. lbs.).
NOTE: The left engine mount isolator has a locating dowel that aligns to a crossmember mount locating hole.
8. Align flex plate to drive plate and install mounting bolts. Torque bolts to 75 Nm (55 ft. lbs.).
9. Install bell housing inspection cover.
10. Install crankshaft position sensor.
11. Install starter and connect electrical wiring.
12. Connect exhaust system at manifold using new V-Band clamps. Tighten V-Band clamps to 12 Nm (100 inch lbs.).
13. Install oil filter.
14. Lower vehicle.
15. Install power steering pump and generator.
16. Install receiver/dyer and air conditioning lines.
17. Connect air conditioning pressure transducer electrical connector.
18. Install air conditioning compressor through front engine compartment opening. While supporting compressor, install compressor bracket to engine.
19. Install compressor to bracket and connect electrical connector.
20. Connect air conditioning lines to compressor.
21. Install air conditioning and accessory drive belts.
22. Connect all electrical connections including ground straps.
23. Connect all vacuum lines.
24. Install heater hoses and attach heater tube to engine bell housing.
25. Connect fuel line.
26. Install coolant pressure bottle.
27. Install radiator/condenser and connect air conditioning lines to condenser.
28. Install upper intake manifold.
29. Install air intake duct.
30. Evacuate and charge air conditioning system.
31. Install radiator hoses. Fill cooling system.
32. Install fan module. Connect electrical connector, and wiring harness to lower left corner of fan module.
33. Install upper radiator crossmember and engine compartment supports.
34. Install right headlamp module.
35. Install hood and hood side panels.
36. Fill engine crankcase with proper oil to correct level.
37. Connect battery.
38. Start engine and run until operating temperature is reached.
39. Check and adjust fluid levels as needed.