Engine, Removing

Special tools and workshop equipment required

Disconnect Tool 8875A
Scissor Lift Table VAS 6131
Powertrain Support Posts J-48839
Driver Side Engine Lifting Bracket 10242-1
Passenger Side Engine Lifting Bracket 10242-2

Fig 1: Identifying Engine Cover

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-- Release the fuel system pressure. Refer to FUEL SYSTEM PRESSURE RELEASE PROCEDURE .

-- Disconnect the positive (1) and negative (3) battery cables. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Remove the engine cover (1).

-- Recover the refrigerant from the refrigerant system. Refer to Description and Operation .

Fig 2: Identifying Belly Pan And Bolts, Removal & Installation

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-- Raise and support the vehicle.

-- Remove the belly pan.

-- Drain the cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING .

-- Drain the engine oil.

Fig 3: Identifying Mounting Bracket

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-- Lower the vehicle.

-- Remove the electric vacuum pump and mounting bracket (1). Refer to Removal and Installation .

Fig 4: Air Cleaner Body

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-- Remove the air cleaner body (1). Refer to AIR CLEANER HOUSING .

Fig 5: Identifying Resonator

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-- Remove the resonator. Refer to AIR CLEANER RESONATOR

Fig 6: Identifying Coolant Recovery Bottle

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-- Remove the coolant recovery bottle (1). Refer to COOLANT RECOVERY RESERVOIR .

Fig 7: Identifying Hose Retainer And Upper Radiator Hose

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-- Disengage the hose retainer (1) from the intake manifold and remove the upper radiator hose (2).

Fig 8: Cooling Fan & Serpentine Belt

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-- Remove the cooling fan module (1). Refer to COOLING FAN .

Fig 9: Identifying Heater Core Supply Hose

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-- Disconnect the heater core supply hose (1).

Fig 10: Identifying Heater Core Return Hose

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-- Disconnect the heater core return hose (1).

Fig 11: Serpentine Belt With Routing

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-- Remove the accessory drive belt (7). Refer to ACCESSORY DRIVE BELT .

Fig 12: Generator Field Electrical Connector & Generator Retainers

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-- Remove the generator (2). Refer to GENERATOR (CJRA) .

Fig 13: Identifying Electrical Connectors And Fuel Purge Solenoid Wire Harness Retainer

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-- Disconnect the electrical connector (3) from the fuel purge solenoid.

-- Disengage the fuel purge solenoid wire harness retainer (1) from the engine cowl.

-- Disconnect the electrical connector (2) from the A/C pressure transducer.

Fig 14: Identifying Variable Valve Timing Solenoid Connectors

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NOTE: Mark the variable valve timing solenoid connectors (2) with a paint pen or equivalent so that they may be reinstalled in their original locations.

-- Disconnect the electrical connectors (2) from the variable valve timing solenoids on the left cylinder head cover.

-- Disengage three wire harness retainers (1) from the left cylinder head cover.

Fig 15: Identifying Upper Wire Harness Retainers

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-- Disengage two upper wire harness retainers (2) from the intake manifold support brackets.

-- Disengage two lower wire harness retainers (3) from the intake manifold support brackets.

Fig 16: Identifying Engine Coolant Temperature (ECT) Sensor Connector And Left Camshaft Position (CMP) Sensor

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-- Disconnect the Engine Coolant Temperature (ECT) sensor connector (3).

-- Disconnect the left Camshaft Position (CMP) sensor (5).

-- Disengage one main wire harness retainer (2) from the cylinder head cover and one main wire harness retainer (4) from the cylinder head cover mounting stud.

-- Disengage the main wire harness retainer (1) form the rear of the lower intake manifold.

Fig 17: Identifying Engine Injection/Ignition Harness And Engine Oil Pressure/Temperature Harness

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-- Disconnect the main harness from the engine injection/ignition harness (1) at the rear of the left cylinder head.

-- Disconnect the main harness from the engine oil pressure/temperature harness (2) at the rear of the left cylinder head.

Fig 18: Identifying Electrical Connectors And Wire Harness Retainers

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NOTE: Mark the variable valve timing solenoid connectors (2) with a paint pen or equivalent so that they may be reinstalled in their original locations.

-- Disconnect the electrical connectors (2) from the variable valve timing solenoids on the right cylinder head.

-- Disengage two wire harness retainers (1) from the right cylinder head cover.

Fig 19: Identifying Positive Crankcase Ventilation (PCV), Vapor Purge And Brake Booster

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-- Disconnect the electrical connectors from the Manifold Absolute Pressure (MAP) sensor (1) and the Electronic Throttle Control (ETC) (7).

-- Disengage the ETC harness from the clip (8) on the throttle body. Disengage the wire harness retainers (4 and 5) from the upper intake manifold near the MAP sensor and reposition the wire harness.

-- Disconnect the following hoses from the upper intake manifold:

Positive Crankcase Ventilation (PCV) (3)
vapor purge (6)
brake booster (2)

Fig 20: Identifying Electrical Connector And Wire Harness Retainers

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-- Disconnect the electrical connector (1) from the right Camshaft Position (CMP) sensor.

-- Disengage the wire harness retainer (3) from the intake manifold support bracket.

-- Disengage the wire harness retainer (2) from the upper intake manifold support bracket mounting stud.

Fig 21: Exploded View Of Wheel Assembly

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-- Raise and support the vehicle.

-- Remove both front tire and wheel assemblies (1). Refer to Removal and Installation .

Fig 22: Identifying Left Lower Splash Shield

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-- Remove the left lower splash shield (2).

Fig 23: Identifying Right Lower Splash Shield

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-- Remove the right lower splash shield (2).

Fig 24: Identifying Drive Axles

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-- Remove both drive axles (2) and the intermediate shaft. Refer to Removal and Installation

Fig 25: Identifying Crossunder Pipe

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-- Remove the front fore and aft crossmember (1).

-- Remove the crossunder pipe (2). Refer to EXHAUST CROSSUNDER PIPE

-- Disconnect the oxygen sensor connectors from the main wire harness and remove both catalytic converters (3). Refer to CATALYTIC CONVERTER .

Fig 26: Identifying Front Engine Mount Bracket With Bolts

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-- Remove the three bolts (2) and the front engine mount bracket (1).

Fig 27: Field Generator Connector, B+ Retainer And B+ Cable

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-- Remove the starter. Refer to STARTER (CJRA) .

Fig 28: Identifying Lower Radiator Hose

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-- Remove the lower radiator hose (1).

Fig 29: Identifying A/C Compressor

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-- Remove the A/C compressor (1) from the engine compartment. Refer to Removal and Installation .

Fig 30: Identifying Rear Engine Mount Heat Shield With Bolts

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-- Remove two bolts (1) and the rear engine mount heat shield (2).

Fig 31: Identifying Heat-Shield

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-- Push back the heat-shield (1) from the Crankshaft Position (CKP) sensor.

Fig 32: Identifying Crankshaft Position (CKP) Sensor Electrical Connector, Wire Harness Retainers And Downstream Oxygen Sensor Connector

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-- Disconnect the Crankshaft Position (CKP) sensor electrical connector (3).

-- Disengage one wire harness retainer (2) from the engine block and one wire harness retainer (1) from the transmission mounting stud.

-- Disengage the downstream oxygen sensor connector (4) from the engine mount.

-- Disconnect and reposition the power cord from the engine block heater (if equipped).

Fig 33: Identifying Power Steering Pump Heat Shield With Bolts

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-- Remove three bolts (2) and the power steering pump heat shield (1).

Fig 34: Identifying Wire Harness Retainer

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-- Disengage the wire harness retainer (2) from the power steering pump.

-- Remove three bolts (1) and reposition the power steering pump and bracket as an assembly. >>Do not<< disconnect the power steering lines from the pump.

Fig 35: Identifying Oil Pump Solenoid Electrical Connector And Wire Harness Retainer

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-- Disconnect the oil pump solenoid electrical connector (2).

-- Disengage the wire harness retainer (1) from the engine block.

Fig 36: Identifying Main Wire Harness Retainers

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-- Disengage three main wire harness retainers (1) from the right cylinder head cover.

Fig 37: Identifying Rear Engine Mount Isolator Bolt

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-- Remove the bolt (3) from the rear engine mount isolator.

-- Remove four bolts (2) and the rear engine mount bracket (1).

Fig 38: Identifying Transmission Torque Converter Housing Dust Cover And Rubber Plugs

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NOTE: If the transmission is to be eventually separated from the engine, removal of the torque converter bolts and lower transmission mounting bolts are best accomplished at this time.

-- If required, remove the transmission torque converter housing dust cover (1) and rubber plugs (2).

Fig 39: Identifying Torque Converter-To-Flexplate Bolt And Transmission-To-Engine Lower Bolts

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-- If required, remove the torque converter-to-flexplate bolts (1). Upon removing the bolts, a tight-tolerance (slotted) bolt will be encountered. Mark this location (flexplate and converter) with paint for assembly reference.

-- If required, remove the four transmission-to-engine lower bolts (2).

Fig 40: Identifying Transmission Solenoid Harness Connector And Main Wire Harness Retainer

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-- Lower the vehicle.

-- Disconnect transmission solenoid harness connector (2).

-- Disengage the main wire harness retainer (1) from the valve body pan.

Fig 41: Identifying Transmission Input Shaft Speed Sensor Connector And Oil Cooler Lines

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-- Disconnect the transmission input shaft speed sensor connector (1).

-- Disconnect the oil cooler lines (2) from transmission using disconnect tool 8875A.

Fig 42: Identifying Gearshift Cable And Transmission Manual Valve Lever

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-- Disconnect the gearshift cable (1) from transmission manual valve lever (2).

Fig 43: Identifying Gearshift Cable, Bracket, Output Shaft Speed Sensors Connectors, Wire Harness Retainer And Gearshift Cable Bracket

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-- Disconnect the gearshift cable (5) from the bracket (4).

-- Disconnect two output shaft speed sensors connectors (2 and 3).

-- Disengage the wire harness retainer (1) from the gearshift cable bracket (4).

Fig 44: Identifying Fuel Line

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-- Disconnect the fuel line (1) from the fuel rail inlet. Refer to QUICK CONNECT FITTING DISCONNECTING AND CONNECTING

-- Reposition the main wire harness away from the engine.

-- Raise and position vehicle height to allow scissor lift table VAS 6131 (2) and powertrain support posts J-48839 (1) to be installed under the engine/transmission assembly.

Fig 45: Identifying Scissor Lift Table VAS 6131 And Powertrain Support Posts J-48839

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-- Loosen the cradle engine mounts to allow movement for positioning onto the engine locating holes on the engine block and oil pan rail. Lower the vehicle and position cradle until the engine is resting on the powertrain support posts J-48839. Tighten the powertrain support posts J-48839 to the cradle frame. Secure the engine/transmission assembly to the scissor lift table VAS 6131 with safety straps.

Fig 46: Identifying LH Engine (Transmission) Mount Bracket Bolts

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-- Lower the vehicle so that the weight of the engine and transmission ONLY is on the cradle.

-- Remove two bolts (1) from the LH engine (transmission) mount bracket (2).

Fig 47: Identifying RH Engine Mount Bracket Bolts

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-- Remove three bolts (1) from the RH engine mount bracket (2).

-- Slowly raise the vehicle in short length spans. Inspect at each interval for potential engine or transmission contact to vehicle components. Move the cradle/dolly fixture as necessary to allow for removal clearance.

Fig 48: Identifying Transmission Upper Bellhousing-To-Block Bolts, Transmission And Engine

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NOTE: Perform the following steps to remove the transmission from the engine if required.

-- Position a transmission jack under the transmission. Secure the transmission to the transmission jack.

-- Remove the remaining six transmission upper bellhousing-to-block bolts (3).

-- Remove the transmission (2) and spacer plate from the engine (1).

Fig 49: Identifying Air Inlet Hose And Upper Intake Manifold

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NOTE: Perform the following steps to remove the engine from the cradle/dolly fixture if required.

-- Remove the upper intake manifold (2). Refer to UPPER INTAKE MANIFOLD .

Fig 50: Identifying Upper Intake Manifold Support Brackets And Bolts

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-- Remove the bolts (2) and remove the upper intake manifold support brackets (1).

Fig 51: Identifying Heater Core Supply Tube And Bolts

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-- Remove two bolts (2) and the heater core supply tube (1).

Fig 52: Identifying Driver Side Engine Lifting Bracket 10242-1 And Bolts

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-- Install the driver side engine lifting bracket 10242-1 (1) on the LH cylinder head with bolts (2) provided with the Engine Lifting Bracket. Tighten the bolts to 21 Nm (15 ft. lbs.).

Fig 53: Identifying Passenger Side Engine Lifting Bracket 10242-2 And Bolts

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-- Install the passenger side engine lifting bracket 10242-2 (1) on the RH cylinder head with bolts (2) from the Engine Lifting Bracket. Tighten the bolts to 21 Nm (15 ft. lbs.).

Fig 54: Identifying Load-Leveling Lifting Sling, Engine Lifting Brackets And Engine Hoist

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-- Position a load-leveling lifting sling (2), such as OTC® 4305 Engine Load Leveler or equivalent, between the engine lifting brackets (3) and an engine hoist (1).

-- Remove the engine from the cradle/dolly fixture.

-- If required, remove the following components for installation on the replacement engine:

Accessory drive belt tensioner.
Upper intake manifold support bracket.
Block heater (if equipped).