Special Tools

1. Remove the hood. Refer to Hood Replacement.
2. Place fender covers over both fenders.
3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
4. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
5. Remove the radiator. Refer to Radiator Replacement.
6. Remove the intake manifold. Refer to Intake Manifold Replacement.
7. Disconnect the oil pressure sensor and the oxygen sensors from the rear of the engine.



8. Disconnect the engine coolant temperature (ECT) sensor (1).
9. Remove the ground terminal bolt (2).
10. Remove the retaining clips (3, 4) from the brackets.
11. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.
12. Remove the starter. Refer to Starter Motor Replacement.



13. Disconnect the following connectors:

•	Left and right side knock sensor electrical connector (1).

•	A/C pressure switch electrical connector (2).

•	Block heater electrical connector.




14. Remove the ground terminal bolt (1).
15. Remove the engine harness bracket bolt (3).



16. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor.



17. Disconnect the engine wiring harness electrical connector (9) from the camshaft position (CMP) sensor wire harness.



18. Remove the battery cable channel bolt.
19. Remove the battery cable channel from the oil pan.
20. Lower the vehicle.
21. Gather all branches of the engine wiring harness and reposition the harness off to the side.



22. Disconnect the engine wiring harness electrical connector (1) from the generator.
23. Reposition the engine wiring harness/positive battery cable boot (5).
24. Remove the engine wiring harness/positive battery cable nut from the generator.
25. Remove the engine wiring harness/positive battery cable (2) from the generator.



26. Using J 38185 , remove the inlet hose from the water outlet.



27. Using J 38185 , remove the outlet hose (1) from the water outlet.
28. Remove the heater inlet and outlet hoses. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement.
29. Raise the vehicle.
30. Remove the catalytic converters. Refer to Catalytic Converter Replacement - Left Side and Catalytic Converter Replacement - Right Side.
31. Remove the 3 bracket bolts from both the right and the left side engine mounts. Refer to Engine Mount Replacement - Left Side and Engine Mount Replacement - Right Side



32. Remove the torque converter bolts.
33. Remove the transmission oil level indicator tube. Refer to Transmission Fluid Filler Tube and Seal Replacement.



34. Remove the transmission fluid cooler lines from the retainer located on the right side of the engine.



35. Remove the lower transmission bolts (1) on the right and left side.



36. Remove the lower transmission bolt/studs.
37. Lower the vehicle.
38. Remove the 3 upper transmission bolts/studs (1).
39. Install an engine hoist to J 41798 .
40. Install a floor jack under the transmission for support.
41. Separate the engine from the transmission.
42. Remove the engine.
43. Install the engine to an engine stand.
44. Install J 21366 .

1. Remove J 21366 .
2. Install an engine hoist to J 41798 .
3. Remove the engine from the engine stand.
4. Install the engine.
5. Mate the engine to the transmission.
6. Remove the floor jack from under the transmission for support.

Caution: Refer to Fastener Caution in the Preface section.

7. Install the 3 upper transmission bolts/studs (1) and tighten to 50 N·m (37 lb ft).
8. Raise the vehicle.
9. Install the lower transmission bolt/studs and tighten to 50 N·m (37 lb ft).



10. Install the lower transmission bolts (1) on the right and left side and tighten to 50 N·m (37 lb ft).



11. Install the transmission fluid cooler lines to the right side of the engine.
12. Install the transmission oil level indicator tube. Refer to Transmission Fluid Filler Tube and Seal Replacement.



13. Install the torque converter bolts and tighten to 60 N·m (44 lb ft).
14. Install the 3 bracket bolts from both the right and the left side engine mounts. Refer to Engine Mount Replacement - Left Side and Engine Mount Replacement - Right Side
15. Install the catalytic converters. Refer to Catalytic Converter Replacement - Left Side and Catalytic Converter Replacement - Right Side.
16. Lower the vehicle.
17. Install the heater inlet and outlet hoses. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement.



18. Using J 38185 , install the outlet hose (1) to the water outlet.



19. Using J 38185 , install the inlet hose to the water outlet.



20. Install the engine wiring harness/positive battery cable (2) to the generator.
21. Install the engine wiring harness/positive battery cable nut to the generator and tighten the nut to 9 N·m (80 lb in).
22. Position the engine wiring harness/positive battery cable boot (5).
23. Connect the engine wiring harness electrical connector (1) to the generator.



24. Gather all branches of the engine wiring harness and position the harness over the engine.
25. Raise the vehicle.
26. Install the starter. Refer to Starter Motor Replacement.



27. Connect the following connectors:

•	Block heater electrical connector.

•	A/C pressure switch electrical connector (2).

•	Left and right side knock sensor electrical connector (1).




28. Connect the engine wiring harness electrical connector (9) to the CMP sensor wire harness.



29. Connect the engine wiring harness electrical connector (1) to the CKP sensor.



30. Install the battery cable channel to the oil pan.
31. Install the battery cable channel bolt and tighten to 12 N·m (106 lb in).



32. Install the engine harness bracket bolt (3).
33. Install the ground terminal bolt (1) and tighten to 25 N·m (18 lb ft).



34. Install the retaining clips (3, 4) to the brackets.
35. Install the ground terminal bolt (2) and tighten to 25 N·m (18 lb ft).
36. Connect the ECT sensor (1).
37. Connect the oil pressure sensor and the oxygen sensors at the rear of the engine.
38. Lower the vehicle.
39. Install the intake manifold. Refer to Intake Manifold Replacement.
40. Install the radiator. Refer to Radiator Replacement.
41. Recharge the refrigerant. Refer to Refrigerant Recovery and Recharging.
42. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
43. Remove the fender covers from both fenders.
44. Prelube the engine. Refer to Engine Prelubing.
45. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn.
46. Install the hood. Refer to Hood Replacement.

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

47. Test the vehicle using the following procedure:

47.1.

Disable the ignition system.

47.2.

Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.

47.3.

Enable the ignition system.

47.4.

Start the engine and listen for unusual noises.

47.5.

Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.

47.6.

Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.

47.7.

Listen for sticking lifter and other unusual noises.

47.8.

Inspect for fuel, oil and/or coolant leaks while the engine is running.

47.9.

Close the hood.