Engine

The following engine removal and installation procedures are for the engine (6007) only, without the transmission attached.

Removal

1. Drain the cooling system and the crankcase. Remove the hood (16612). Remove the air cleaner outlet tubes (9B659).

2. Disconnect the battery ground cable (14301). Disconnect the heater water hose (18472) from the water pump (8501) and clutch pressure plate (7563). Disconnect the fuel lines at the fuel injection supply manifold. Refer to Section 03-04A.

3. Remove the radiator (8005) and fan shroud (8146). Refer to Section 03-03.

4. NOTE: The fan clutch (8A616) hub has a right-hand thread.

   Remove the fan blade (8600), fan clutch water pump pulley (8509) and drive belt (8620). Refer to Section 03-05.

   

5. Disconnect the accelerator cable (9A758) at the throttle body (9E926).

   Disconnect power brake vacuum line at the intake manifold (9424).

6. Disconnect the exhaust manifolds (9430) from the dual converter Y pipe (5F250). Disconnect the battery to starter relay cable (14300) at the engine. Disconnect secondary air injection system.

7. Disconnect the engine control sensor wiring (12A581) from powertrain control module (PCM) (12A650).

8. Disconnect the engine gauge feed wire (14289) at the ignition coil, engine coolant temperature sensor (ECT sensor) (12A648) and oil pressure sensor (9278). Position the engine gauge feed wire out of the way.

9. Remove the generator mounting bolts and position the generator (GEN) (10346) out of the way, leaving the wires attached.

10. Remove the power steering pump (3A674) from the mounting brackets and position it right side up and to one side, leaving the lines attached.

11. If equipped with an A/C compressor (19703), discharge the air conditioner system. Refer to Section 12-00. Disconnect the A/C manifold and tube assembly at the compressor. Disconnect vacuum signal line to the manifold absolute pressure sensor (MAP sensor) (9F479).

12. Disconnect vacuum jumper harness to reservoir.

13. Remove purge lines from throttle body.

14. Remove supply and return fuel lines with Fuel Line Removal Tool T93T-9550-AH.

15. Raise the vehicle. Remove the starter motor (11001) (and the automatic transmission fluid filler tube bracket, if so equipped). Remove the engine rear plate upper right bolt.

16. On a vehicle with a manualtransmission (7003), remove all the flywheel housing lower attaching bolts. Disconnect the clutch slave cylinder (7A508).

17. On a vehicle with an automatic transmission, remove the transmission housing cover (7986) assembly. Remove the flywheel-to-converter nuts and secure the torque converter (7902) assembly in the housing.

18. Remove the transmission oil cooler lines from the retaining clip at the engine. Remove the converter housing-to-engine lower attaching bolts.

19. Remove the insulator-to-intermediate support bracket nut from each engine front support.

20. Lower the vehicle and position Rotunda Transmission Jack 164-R3510 or equivalent under the transmission to support it.

21. Remove the remaining flywheel or converter housing-to-engine bolts.

22. Attach Engine Lifting Bracket T70P-6000 and Rotunda Universal Load Positioning Sling 014-00036 or equivalent.

23. Using Rotunda Floor Crane 014-00133 or equivalent, raise the engine slightly and carefully pull it from the transmission. Lift the engine out of the chassis.

Installation

1. NOTE: If the engine will not mate properly to the transmission after the crankshaft (6303) enters the transmission housing, turn the crankshaft slowly (with the transmission in gear) until the crankshaft splines mesh with the clutch disc splines.

   Lower the engine carefully into the chassis. Make sure the dowels in the block engage the holes in the converter housing.

2. On a vehicle with an automatic transmission, start the torque converter pilot into the crankshaft. Remove the retainer securing the torque converter in the housing.

3. On a vehicle with a manual transmission, start the input shaft (7017) into the clutch disc (7550). It may be necessary to adjust the position of the transmission with relation to the engine if the input shaft will not enter the clutch disc.

4. Install the converter or flywheel housing upper attaching bolts. Remove the jack supporting the transmission. Refer to Section 07-01A (E4OD), Section 07-01B (C6), Section 07-01C (4R70W) or Section 08-01 for torque specifications.

5. Lower the engine onto the engine support(s) and remove the lifting sling.

6. Install the engine left and right support insulator-to-intermediate support bracket attaching nuts and washers. Tighten the nuts to 73-100 Nm (54-74 lb-ft). Install the transmission oil cooler line clip (7N291).

7. Install the remaining converter or flywheel housing attaching bolts.

8. Install the starter motor and connect the battery to starter relay cable. Attach the automatic transmission fluid filler tube bracket, if so equipped.

   On a vehicle with an automatic transmission, install the transmission oil cooler lines in the transmission oil cooler line clip.

9. Install the exhaust manifold-to-muffler inlet pipe lockwashers and nuts. Tighten the nuts to 34-49 Nm (25-36 lb-ft).

10. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.

    Connect battery to starter relay cable to engine ground connections and the battery ground cable.

11. Connect engine control sensor wiring.

12. On a vehicle with an automatic transmission, connect the transmission kickdown cable to the throttle body.

13. Connect the accelerator cable to the throttle body and install the accelerator control splash shield (9E766).

14. Reconnect power brake vacuum line to the intake manifold vacuum outlet fitting and cap (9A474).

15. Connect the coil primary wire, oil pressure and coolant temperature sending unit wires, flexible fuel line, heater hoses and the battery positive cable.

16. Install secondary air injection pump (AIR pump) (9A486) and tighten bolts to 30-40 Nm (22-30 lb-ft).

17. Install generator (GEN) (10300) to generator mounting bracket (10153). Tighten top bolt to 22-28 Nm (16-21 lb-ft). Tighten outside bolt to 53-72 Nm (40-53 lb-ft).

18. Install A/C compressor to A/C compressor mounting bracket (2882) and tighten to 30-40 Nm (22-30 lb-ft).

19. Install power steering pump to A/C compressor mounting bracket and tighten to 40-55 Nm (30-40 lb-ft).

20. NOTE: The fan clutch hub has a right-hand thread.

    Install the water pump pulley, fan clutch, fan and drive belt. Tighten the fan bolts to 16-24 Nm (12-18 lb-ft).

21. Install the radiator and fan shroud. Connect the lower radiator hose (8286) to the water pump and the upper radiator hose (8260) to the water outlet connection. Connect the A/C manifold and tube (19D734). Refer to Section 03-03 for torque specifications.

22. On a vehicle with an automatic transmission, connect the oil cooler lines. Refer to Section 03-03 for torque specifications.

23. Install and adjust the hood.

24. Fill and bleed the cooling system. Refer to Section 03-03. Fill the crankcase with motor oil specified in Section 00-03. Operate the engine at fast idle and check all hose connections and gaskets for leaks.

25. Perform Quick Test to check the function of the PCM system. Refer to Powertrain Control/Emissions Diagnosis Manual OBDII.

26. On a vehicle with a manualtransmission, check for correct clutch operation.

27. On a vehicle with an automatic transmission, adjust the transmission control linkage. Refer to Section 07-05. Check the fluid level and add as required to bring it to the proper level on the oil indicator.

28. Install the air cleaner outlet tube.