Removal and Replacement

Engine Replacement

Tools Required

J 41427 Engine Lift Brackets

Removal Procedure




1. Raise the hood to the service position, perform the following:

1. Remove the hood hinge bolts (1).
2. Raise the hood until vertical.
3. Install the hood hinge bolts until snug in the service position (2).

2. Disconnect the negative battery cable.
3. Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill).
4. Remove the fuel pipes/hoses.
5. Remove the lower fan shroud.
6. Remove the drive belt.
7. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.




8. If equipped, remove the oil pan skid plate bolts and plate.
9. If equipped, remove the engine shield. Refer to Engine Shield Replacement.
10. Remove the starter.




11. Remove the transmission cover.




12. Remove the positive battery cable clip bolt (2).
13. Remove the catalytic converter.




14. Remove the battery cable bracket bolts.




15. Disconnect the crankshaft position (CKP) sensor electrical connector (5) and remove the harness from the retainer clip.
16. Remove the ground bolt (3) holding the negative battery cable (6) and ground cable (4) to the engine.




17. If equipped, remove the torque converter bolts.
18. Remove the transmission bolts.
19. Lower the vehicle.




20. Reposition the radiator inlet hose clamp.
21. Remove the radiator inlet hose from the thermostat housing.




22. Reposition the radiator outlet hose clamps.
23. Remove the radiator outlet hose from the surge tank.
24. Remove the radiator outlet hose from the water pump.




25. Disconnect the following electrical connectors:

* The A/C pressure switch (1), if equipped
* The air conditioning (A/C) compressor clutch (2), if equipped

26. If equipped, remove the air conditioning (A/C) hoses. Refer to Discharge Hose Replacement (LY2, LMF, L76 and L92) Discharge Hose Replacement (LMM) and Suction Hose Replacement (LY2, LMF, L76 and L92) Suction Hose Replacement (LMM).
27. Remove the positive cable nut and cable from the generator.




28. Remove the engine wiring harness clips (1, 2) from the engine harness brackets.




29. Remove the engine wiring harness rear bracket bolts and bracket.




30. Disconnect the following electrical connectors:

* Evaporative emission (EVAP) canister purge solenoid valve (1)
* Manifold absolute pressure (MAP) sensor

31. Disconnect the engine wiring harness electrical connector (2) from the throttle body.




32. Disconnect the following electrical connectors:

* Knock sensor (1)
* Camshaft position (CMP) sensor (2)
* Fuel pump/oil pressure sensor (3)

33. Remove the harness ground bolt.
34. Reposition the harness ground (4) and ground strap (5).




35. Remove the engine wiring harness bracket nuts.
36. Remove the engine wiring harness bracket from the studs.




37. Remove the junction block bracket bolt.
38. Reposition the bracket and wiring harness aside.




39. Remove the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve.
40. Remove the stud holding the engine wiring harness bracket.
41. Reposition the engine wiring harness with the bracket aside.
42. Remove the heater hoses.



43. Disconnect the EVAP canister harness (1) from the purge solenoid valve.




44. Disconnect the engine wiring harness electrical connector (7) from the ignition coil.
45. Disconnect the power brake booster vacuum hose from the vacuum fitting.




46. Loosen the power steering (P/S) pump rear bracket nut.
47. Remove the P/S pump rear bracket front nut.
48. Remove the bolts and the nut for the P/S pump bracket.
49. Leave the A/C compressor, if equipped, and the P/S pump on the bracket.
50. Slide the P/S pump bracket forward off the stud and set aside.
51. Remove the thermostat and water outlet.




52. Remove the left front and right rear intake manifold lower bolts.
53. Install J 41427 to the left front and right rear intake manifold bolts, using the following procedure:

1. Install the J 41427 marked RIGHT REAR.

Notice: Refer to Fastener Notice.

2. Install the lift bracket bolts.

Tighten the bolts to 15 N.m (11 lb ft).

3. Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of the engine.
4. Install the lift bracket bolts.

Tighten the bolts to 15 N.m (11 lb ft).

54. Install a suitable lifting devise to the engine lift brackets.




55. Remove the engine mount to engine mount bracket nuts.
56. Support the transmission with a suitable floor jack.
57. Remove the engine.

Installation Procedure




1. Install the engine.

Notice: Refer to Fastener Notice.

2. Install the engine mount to engine mount bracket bolts.

Tighten the bolts to 65 N.m (48 lb ft).




3. Remove the lifting devise and the J 41427.
4. Apply threadlock to the threads of the intake manifold lower bolts.
5. Install the intake manifold bolts.

1. Tighten the bolts a first pass to 3 N.m (27 lb in).
2. Tighten the bolts a second pass to 12 N.m (106 lb in).
3. Tighten the bolts a final pass to 15 N.m (11 lb ft).

6. Install one transmission bolt until snug.
7. Remove the support jack from under the transmission.
8. Install the thermostat and water outlet.




9. Slide the P/S pump bracket onto the stud.
10. Install the bolts and the nut for the P/S pump bracket.
11. Install the P/S pump rear bracket front nut.
12. Tighten the P/S pump rear bracket nut.

Tighten the bolts and nuts to 41 N.m (30 lb ft).

13. Connect the power brake booster vacuum hose to the vacuum fitting.




14. Connect the engine wiring harness electrical connector (7) from the ignition coil.




15. Connect the EVAP canister harness (1) to the purge solenoid valve.
16. Install the heater hoses.




17. Position the engine wiring harness.
18. Install the stud holding the engine wiring harness bracket.
19. Install the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve.

Tighten the nut to 9 N.m (80 lb in).




20. Position the bracket and wiring harness.
21. Install the junction block bracket bolt.

Tighten the bolt to 25 N.m (18 lb ft).




22. Install the engine wiring harness bracket to the studs.
23. Install the engine wiring harness bracket nuts.

Tighten the nuts to 12 N.m (106 lb in).




24. Position the harness ground (4) and ground strap (5).
25. Install the harness ground bolt.

Tighten the bolt to 16 N.m (12 lb ft).

26. Connect the following electrical connectors:

* Knock sensor (1)
* CMP sensor (2)
* Fuel pump/oil pressure sensor (3)




27. Connect the engine wiring harness electrical connector (2) to the throttle body.
28. Connect the following electrical connectors:

* EVAP canister purge solenoid valve (1)
* MAP sensor




29. Place the engine wiring harness rear bracket onto the upper intake manifold and install the bolts.

Tighten the bolts to 10 N.m (89 lb in).




30. Install the engine wiring harness clips (1, 2) to the engine harness brackets.




31. If equipped, install the A/C hoses. Refer to Discharge Hose Replacement (LY2, LMF, L76 and L92) Discharge Hose Replacement (LMM) and Suction Hose Replacement (LY2, LMF, L76 and L92) Suction Hose Replacement (LMM).
32. Connect the following electrical connectors:

* The A/C compressor clutch (2), if equipped
* The A/C pressure switch (1), if equipped




33. Install the radiator outlet hose to the water pump.
34. Install the radiator outlet hose to the surge tank.
35. Position the radiator outlet hose clamps.




36. Install the radiator inlet hose to the thermostat housing.
37. Position the radiator inlet hose clamp.
38. Install the drive belt.
39. Install the lower fan shroud.
40. Install the fuel pipes/hoses.




41. Remove the hood hinge bolt from the service position (2).
42. Lower the hood to the normal position.
43. Install the hood hinge bolts.

Tighten the bolts to 25 N.m (18 lb ft).

44. Raise the vehicle.




45. Install the transmission bolts.

Tighten the bolts to 50 N.m (37 lb ft).

46. If equipped, install the torque converter bolts.

Tighten the bolts to 63 N.m (47 lb ft).




47. Install the ground bolt (3) holding the negative battery cable (6) and ground cable (4) to the engine.
48. Connect the CKP sensor electrical connector (5) and install the harness to the retainer clip.




49. Install the battery cable bracket bolts.

Tighten the bolts to 12 N.m (106 lb in).

50. Install the catalytic converter.




51. Install the positive battery cable clip bolt (2).




52. Install the transmission cover.

Tighten the bolts to 12 N.m (106 lb in).

53. Install the starter.
54. If equipped, install the engine shield. Refer to Engine Shield Replacement.




55. If equipped, install the oil pan skid plate and bolts.

Tighten the bolts to 20 N.m (15 lb ft).

56. Lower the vehicle.
57. Connect the negative battery cable.
58. Perform the engine prelube procedure.
59. Add engine oil supplement to the engine oil. Refer to Sealers, Adhesives, and Lubricants for the correct part number.
60. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Vac-N-Fill).
61. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging.

Important: After an overhaul, the engine should be tested. Use the following procedure after the engine is installed in the vehicle.

62. Disable the ignition system.
63. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
64. Start the engine and listen for unusual noises.
65. Check the oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
66. If necessary, install an oil pressure gage and measure the oil pressure.
67. Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.
68. Listen for sticking valve lifters, or other unusual noises.
69. Inspect for fuel, oil, and/or coolant leaks while the engine is running.
70. Perform a final inspection for the proper oil and coolant levels.
71. Close the hood.