Removal Procedure
Engine Replacement
Tools Required
* J 38185 Hose Clamp Pliers
* J 44220 Engine Lift Bracket
Removal Procedure
1. Remove the hood.
2. Recover the A/C system.
3. Remove the drive belt.
4. Remove the battery box.
5. Drain the engine coolant.
6. Remove the outlet radiator hose.
7. Remove the radiator.
8. Remove the cooling fan.
9. Remove the air cleaner assembly.
10. Remove the air cleaner resonator and outlet duct.
11. Position the J 38185 to the clamp (3) in order to remove the radiator inlet hose (2) from the water outlet housing (4).
12. Remove the washer solvent container/coolant recovery reservoir mounting bolts ONLY, in order to gain clearance to remove the engine wiring harness.
13. Disconnect the 2 engine wiring harness connectors from the powertrain control module (PCM).
14. Remove the engine wiring harness clips from the wheelhouse.
15. Disconnect the engine wiring harness retainers (1) from the power steering pump (2).
16. Disconnect the engine wiring harness connectors from the following components:
^ The electric motor actuator connector
^ The oil pressure switch
17. Disconnect the engine wiring harness retainer (2) from the camshaft cover (3).
18. Disconnect the engine wiring harness connectors from the following components:
^ The exhaust camshaft position (CMP) sensor (5)
^ The exhaust camshaft actuator (6)
19. Disconnect the engine wiring harness connectors from the following components:
^ The engine coolant temperature (ECT) sensor (1)
^ The fuel injector harness (2)
^ The ignition coils (4)
^ The heated oxygen sensor (HO2S) (5)
20. Disconnect the engine wiring harness retainer (3) from the camshaft cover (4).
21. Disconnect the engine wiring harness connector (2) from the throttle body (1).
22. Disconnect the engine wiring harness connector from the intake CMP sensor.
23. Carefully disengage the engine wiring harness conduit from the camshaft cover.
24. Remove the transmission filler tube, if equipped.
25. Remove the air conditioning (A/C) compressor evaporator hose bracket bolt from the cylinder head.
26. Drain the engine oil, if necessary.
27. Remove the studs securing the secondary air injection (AIR) pipe cover to the cylinder head.
Remove the AIR pipe cover and gasket.
Discard the gasket.
28. Install the J 44220 in place of the AIR adapter.
29. Disconnect the inlet heater hose quick connect (1) from the heater core (2), and secure to the engine.
30. Remove the power steering pump mounting bolts ONLY, and position aside.
31. Remove the right engine mount-to-frame bracket bolt.
32. Disconnect the engine wiring harness retainer from the engine wiring harness bracket.
33. Position the engine wiring harness aside.
34. Disconnect the fuel feed pipe from the fuel rail.
35. Disconnect the evaporative emission (EVAP) pipe at the purge solenoid.
36. Remove the oil level indicator and tube.
37. Remove the manifold absolute pressure (MAP) sensor.
38. Disconnect the MAP sensor wiring harness retainer (4) from the intake manifold.
39. Raise and support the vehicle only high enough to access the wiring harnesses through the wheelhouse.
40. Remove the A/C condenser line bolt at the A/C compressor, remove the line from the compressor, if equipped.
41. Remove the A/C evaporator line bolt at the A/C compressor, remove the line from the compressor, if equipped.
42. Remove the A/C compressor bolts and compressor, if equipped.
43. Disconnect the following wiring harness retainers from the engine wiring harness bracket:
^ The battery cable
^ The engine (4, 6)
^ The MAP sensor (5)
44. Remove the starter solenoid "S" terminal nut (3) and disconnect the lead (4) from the starter.
45. Remove the starter terminal nut (1) and disconnect the battery positive cable (2) from the starter.
46. Remove the bolt (5) securing the battery negative cable ground terminal (4) to the engine block.
47. Disconnect the engine wiring harness connector from the EVAP canister purge solenoid valve.
48. Disconnect the engine wiring harness connector (3) from the # 2 knock sensor (KS) (1).
49. Disconnect the coolant heater cord from the coolant heater, if equipped.
50. Disconnect the engine wiring harness retainers (1, 2) from the A/C compressor and the engine oil pan rail.
51. Position the J 38185 (2) to the clamp (1) in order to remove the heater outlet hose from the heater outlet hose fitting (3).
52. Disconnect the engine wiring harness connector (3) from the crankshaft position (CKP) sensor (1).
53. Raise the vehicle completely.
54. Remove the 3 bolts securing the engine wiring ground leads (2) to the engine block.
55. Disconnect the engine wiring harness retainer (5) from the engine oil pan rail.
56. Position the engine wiring harness aside.
57. Disconnect the fuel line clips from the brackets on the transmission.
58. Remove the crossmember.
59. Remove the front propeller shaft.
60. Remove the differential carrier assembly bushing to frame bolts ONLY.
61. Position the differential carrier assembly forward.
62. Secure the pinion yoke, in order to prevent the differential carrier from rotating.
63. Remove the exhaust seal.
64. Remove the bolt (2) securing the transmission oil cooler pipe bracket to the right side of the engine oil pan rail (automatic only).
65. Remove the inspection plug (3) from the transmission (1) (M30 only).
66. Mark the torque converter to flexplate/flywheel orientation to ensure proper realignment (M30 only).
67. Remove the service slot plug.
68. Repeat the following steps for all 3 torque converter bolts (automatic only):
1. Rotate the harmonic balancer center bolt clockwise ONLY, in order to access the torque converter bolt through the service slot.
2. Remove the torque converter bolts.
69. Lower the transmission slightly.
70. Remove the 9 transmission bolts.
71. Lower the vehicle.
72. Remove the left engine mount-to-frame bracket bolt.
73. Place a jack under the transmission for support.
74. Remove the remaining transmission mounting bolts (2).
75. Install an engine lift chain to the engine lift brackets and attach to an engine lift device.
76. Using the engine lift device, raise the engine only enough to remove the engine mounts.
77. Remove the bolts securing the following to the engine block:
^ The left engine mount
^ The right engine mount
78. Remove the engine mounts.
Important: Ensure clearance is maintained between the engine and the following:
^ The A/C compressor
^ The A/C hoses
^ The engine mounts
^ The engine wiring harness
^ The fuel hose/pipes
^ The heater outlet hose/pipe
^ The power steering pump
^ The transmission input shaft (manual only)
^ The transmission oil cooler pipes (automatic only)
Carefully raise the engine from the engine compartment, ensuring the transmission stays supported.
79. Install the engine to an engine stand.
80. Remove the engine lift chain from the engine lift brackets.