Removal and Replacement

Removal Procedure

^ Tools Required
- J 36857 Lift Brackets

Caution: Refer to Battery Disconnect Caution in Service Precautions.





1. Disconnect the negative battery cable.
2. Remove the wiper arms.
3. Remove the air inlet grilles.
4. Remove the hood.
5. Remove the battery.
6. Recover the refrigerant.
7. Drain the coolant.
8. Remove the intake air resonator.
9. Release the air filter housing from the rubber grommets and remove the air filter housing.

Important: Tag all of the wires removed to prevent improper reinstallation.

10. Disconnect the large wiring harness connectors (1).
11. Remove the body ground wire from the negative battery cable end.
12. Remove the four power supply wires from the battery positive cable end.
13. Siphon the power steering fluid from the power steering reservoir.





14. Release the power steering suction hose clamp and remove the power steering suction hose from the reservoir.





15. Remove the power steering discharge hose fitting (a crow's foot wrench works best) from the power steering pump.

Important: Tag all of the vacuum hoses to aid in reassembly.





16. Remove the brake booster threaded vacuum fitting from the intake plenum (1).
17. Remove the vacuum hoses (2) from the brake power booster hose.





18. Unclip the Engine Control Module (ECM) from the underhood electrical center.
19. Unclip the relays from the electrical center box to enable removal of the entire wiring harness (ECM included) from the electrical center.
20. Drape the entire wiring harness over the top of the engine and secure to prevent interference when removing the engine.
21. Relieve the fuel system pressure. Important: Counterhold the fuel supply and return hose connections to prevent damage to the fuel rail.
Residual fuel may be present in the supply hose, provide a means to capture fuel if necessary.
22. Disconnect the fuel supply and return hose connections.





23. Release the throttle body coolant hose clamp and remove the hose from the throttle body.
24. Remove the vacuum hose from the purge valve located on top of the engine ventilation chamber. (The engine ventilation chamber is located on the rear, passenger side of the engine.)
25. Remove the vacuum hose from the hot water control valve.
26. Release the coolant reservoir hose clamp and remove the hose from the coolant intake pipe.
27. Remove the electric heater water pump screws from the RH side of the engine compartment.
28. Drape the electric heater water pump (with hoses still attached) over the top of the engine and secure.

Important: Use care with the locking tabs on the quick connects, they break easily.





29. Disconnect the heater hose quick connects from the heater core pipes.
29.1. Raise the air inlet screen on the passenger side and open the access door near the pollen filter.
29.2. Squeeze the tabs on the locking collar and pull back on the sleeve to unlock.
29.3. Carefully pull back on the tabs to remove the quick connect from the heater core pipes.
29.4. Discard the green assembly markers (1) if attached.
30. Remove the radiator (with the electric fan attached).
31. Remove the A/C compressor/condenser (HP) hose bracket screws where the bracket connects near the driver's side frame rail.
32. On the LH side engine compartment frame rail, remove the cooling fan resistor screw and position the resistor out of the way to allow for added engine removal clearances.





33. Remove the condenser line bolt from the condenser.
34. Remove the condenser (HIP) line from the condenser and plug the connections to prevent A/C system contamination.
35. Secure the HIP A/C line to the engine with mechanic's wire to prevent interference during engine removal.
36. Disconnect the A/C system quick-connect near the low pressure service valve and plug the connections to prevent A/C system contamination.
36.1. Remove the protective cover.
36.2. Remove the snap ring.
36.3. Remove the A/C hose from the quick-connect.
37. Install the J 36857 to the two engine lift shackles on each side of the engine.
The lift shackles may be located under plastic protectors.
38. Raise and support the vehicle. Refer to Vehicle Lifting.
39. Remove the splash shield bolts.
40. Remove the splash shield.
41. Disconnect the A/C compressor electrical connector.
42. Remove the transmission.





43. Remove the engine mount nuts. Note the orientation of the locator tab (1).
44. Lower the vehicle.
45. Connect the engine lift chains to the lift shackles.
46. Remove the engine.
To enable extra clearances, remove the upper engine mount nuts and allow the engine mounts to fall out of the way once the engine lift has assumed the weight of the engine.
47. Transfer parts as necessary.


Installation Procedure
1. Install the motor mounts to the engine brackets, if removed.
^ Tighten the upper motor mount nuts to 40 Nm (30 ft. lbs.).
2. Install the engine.
3. Remove the engine lift chains from the lift shackles.
4. Raise and support the vehicle.





Important: Ensure the guide pins (1) are in place and install the engine mount nuts.

Notice: Refer to Fastener Notice in Service Precautions.

5. Install the lower engine mount nuts.
^ Tighten the lower engine mount nuts to 55 Nm (41 ft. lbs.).
6. Install the transmission.
7. Connect the A/C compressor electrical connector.
8. Install the splash shield.
9. Install the splash shield bolts.
^ Tighten the splash shield bolts until fully seated.
Do not strip the splash shield, bolts.
10. Lower the vehicle.
11. Remove the J 36857 from the engine lift shackles and replace the plastic covers if removed.
12. Reconnect the A/C system LP quick-connect (near the low pressure service valve):
12.1. Remove the plugs from the fittings.
12.2. Clean the fittings and the surrounding areas.
12.3. Install new O-rings.
12.4. Lubricate the O-rings with mineral oil, 525 viscosity.
12.5. Install the A/C hose into the quick-connect.
12.6. Install the snap ring.
12.7. Install the protective cover.





13. Reconnect the A/C system HP condenser line to the condenser:
13.1. Remove the plugs from the fittings.
13.2. Clean the fittings and the surrounding areas.
13.3. Install new O-rings.
13.4. Lubricate the O-rings with mineral oil, 525 viscosity.
13.5. Install the condenser line into the condenser.
14. Install the condenser line bolt.
^ Tighten the condenser line bolt to 27 Nm (20 ft. lbs.).
15. On the LH side engine compartment frame rail, reposition the cooling fan resistor and install the screw.
^ Tighten the cooling fan resistor screw until fully seated and not stripped.
16. Reposition the A/C compressor/condenser (HP) hose and bracket.
17. Install the A/C compressor/condenser (HP) hose bracket screws where the bracket connects near the driver's side frame rail.
^ Tighten the A/C compressor/condenser hose bracket screws to 8 Nm (71 inch lbs.).
18. Install the radiator (with the electric fan attached).

Important: Ensure the quick connects are fully seated and that the retaining sleeves are pushed in to the locked position.

19. Install the heater hose quick connects to the heater core pipes:





19.1. Discard the green assembly marker (1), if not attached to the quick connect.
19.2. Press the quick connects onto the heater core pipes.
19.3. Inspect that the quick connects are fully seated.
19.4. Squeeze the locking tabs (2) and push the retaining sleeve (3) into the locked position.
19.5. Close and secure the access door near the pollen filter.
19.6. Lower the air inlet screen.
20. Install the electric heater water pump (with the hoses attached) to the RH side of the engine compartment.
^ Tighten the electric heater water pump screws until fully seated and not stripped.
21. Install the coolant reservoir hose and clamp to the coolant intake pipe.





22. Install the vacuum hose to the hot water control valve.
23. Install the vacuum hose to the purge valve located on the engine ventilation chamber.
24. Install the coolant hose and clamp to the throttle body.

Important: Counterhold the hoses, while tightening, to prevent damage to the fuel rail.

25. Install the fuel supply and return hoses.
^ Tighten the fuel hose connections to 15 Nm (11 ft. lbs.).
26. Install the wiring harness to the electrical center box and clip the relays in place.





27. Install the Engine Control Module (ECM) and secure in place.





28. Install the vacuum hoses (2) to the brake power booster hose.
29. Install the brake booster threaded vacuum fitting (1) to the intake plenum.
^ Tighten the brake booster threaded vacuum fitting until fully seated. Do not strip the brake booster threaded fitting.





30. Install the Power steering pump discharge hose to the power steering pump.
^ Tighten the power steering pump discharge hose connection to 28 Nm (21 ft. lbs.).





31. Install the power steering suction hose and clamp.
32. Install the four power supply wires to the battery positive cable end.
33. Install the body ground wire to the battery negative cable end.





34. Connect the large wiring harness connectors (1).
35. Install the air filter housing. Ensure the air filter housing is fully seated in the rubber mounting grommets.
36. Install the air intake resonator.
37. Install the air inlet grilles.
38. Install the wiper arms.
39. Install the hood.
40. Install the battery and connect the cables.
41. Recharge the A/C system.
42. Fill the power steering system.
43. Fill and bleed the cooling system.
44. Leak test the A/C system.
45. Inspect for fluid and exhaust leaks.
46. Bleed the power steering system.
47. Reprogram the applicable accessories. Refer to Reprogramming Accessories After Battery Disconnect in Instrument Panel, Gauges, and Warning Indicators.