For 1990-2009 cars

#### Special Tools

• | J 38185 Hose Clamp Pliers

• | J 44220 Engine Lift Bracket

### Removal Procedure

1. Remove the hood. Refer to Hood Replacement.
2. Remove the battery box. Refer to Battery Box Replacement.
3. Drain the engine coolant. Refer to Cooling System Draining and Filling.
4. Remove the outlet radiator hose. Radiator Outlet Hose Replacement.
5. Remove the cooling fan. Refer to Fan Replacement.
6. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
7. Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement.
8. Remove the generator. Refer to Generator Replacement.
9. Reinstall the engine lift bracket. Refer to Engine Lift Bracket Replacement.
10. Position the J 38185 to the clamp (3) in order to remove the radiator inlet hose (2) from the water outlet housing (4).
11. Remove the washer solvent container/coolant recovery reservoir mounting bolts ONLY, in order to gain clearance to remove the engine wiring harness. Refer to Windshield Washer Solvent Container Replacement.
12. Disconnect the 2 engine wiring harness connectors (2) from the powertrain control module (PCM) (3).
13. Disconnect the engine wiring harness retainers (1) from the wheelhouse (4).
14. Open the engine wiring harness retainer (5).
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 (4WD only)

• | 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 following electrical connectors from the camshaft cover:

• | The fuel injector harness (1)

• | The heated oxygen sensor (HO2S) (2)

• | The engine coolant temperature (ECT) sensor (3)

20. Disconnect the engine wiring harness electrical connectors from the ignition coils.
21. Disconnect the engine wiring harness retainer (3) from the camshaft cover (4).
22. Disconnect the engine wiring harness connector (2) from the throttle body (1).
23. Disconnect the engine wiring harness connector from the intake CMP sensor.
24. Carefully disengage the engine wiring harness conduit from the camshaft cover.
25. Remove the transmission filler tube (M30 only). Refer to Transmission Fluid Filler Tube and Seal Replacement.
26. Drain the engine oil, if necessary. Refer to Engine Oil and Oil Filter Replacement.
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 (1) from the intake manifold (2).
33. Position the engine wiring harness aside.
34. Disconnect the fuel feed pipe from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service.
35. Disconnect the evaporative emission EVAP pipe at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service.
36. Remove the oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement.
37. Disconnect the brake booster hose (6) from the brake booster.
38. Remove the manifold absolute pressure (MAP) sensor. Refer to Manifold Absolute Pressure Sensor Replacement.
39. Disconnect the MAP sensor wiring harness retainer (4) from the intake manifold (5).
40. Raise and support the vehicle only high enough to access the wiring harnesses through the wheelhouse. Refer to Lifting and Jacking the Vehicle.
41. Disconnect the following wiring harness retainers from the engine wiring harness bracket:

• | The battery cable

• | The engine (4, 6)

• | The MAP sensor (5)

42. Remove the starter solenoid "S" terminal nut (3) and disconnect the lead (4) from the starter.
43. Remove the starter terminal nut (1) and disconnect the battery positive cable (2) from the starter.
44. Remove the bolt (4) securing the battery negative cable (5) to the engine block (1).
45. Disconnect the engine wiring harness connector from the evaporative emission (EVAP) canister purge solenoid valve.
46. Disconnect the engine wiring harness connector (3) from the # 2 knock sensor (KS) (1).
47. Disconnect the coolant heater cord from the coolant heater, if equipped.
48. Disconnect the engine wiring harness connector from the # 1 KS (2).
49. Disconnect the engine wiring harness retainer (4) from the engine oil pan rail.
50. Remove the bolt (5) securing the heater outlet hose/pipe to the left engine mount (4).
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. Refer to Lifting and Jacking the Vehicle.
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. Remove the left engine mount-to-frame bracket bolt.
58. Remove the nuts securing the fuel hose/pipe brackets to the transmission (MA5 only).
59. Remove the nuts (2) securing the fuel hose/pipe bracket (1) to the transmission (M30 only).
60. Disconnect the fuel hose/pipe retainer (4) from the range selector cable bracket (3), and position aside the fuel hose/pipe bundle (M30 only).
61. Remove the applicable components in order to gain clearance to remove the engine:

• | RWD

• | Remove the crossmember. Refer to Transmission Support Crossmember Replacement.

• | 4WD

1. | Remove the front propeller shaft. Refer to Front Propeller Shaft Replacement.

2. | Remove the differential carrier assembly bushing to frame bolts ONLY.

3. | Position the differential carrier assembly forward.

4. | Secure the pinion yoke, in order to prevent the differential carrier from rotating.

62. Remove the exhaust seal. Refer to Exhaust Seal Replacement.
63. Remove the bolt (2) securing the transmission oil cooler pipe bracket to the right side of the engine oil pan rail (M30 only).
64. Remove the inspection plug (3) from the transmission (1) (M30 only).
65. Mark the torque converter to flexplate/flywheel orientation to ensure proper realignment (M30 only).
66. Remove the service slot plug.
67. Repeat the following steps for all 3 torque converter bolts (M30 only):

67.1. | Rotate the harmonic balancer center bolt clockwise ONLY, in order to access the torque converter bolt through the service slot.

67.2. | Remove the torque converter bolt using one of the following:

• | 18 mm crowfoot wrench

• | Short T50 TORX bit

68. Remove the 9 transmission mounting bolts (2).
69. Remove the remaining transmission mounting bolts (2).
70. Lower the vehicle.
71. Place a jack under the transmission for support.
72. Install an engine lift chain to the engine lift brackets and attach to an engine lift devise.
73. Using the engine lift devise, raise the engine only enough to remove the engine mounts.
74. Remove the bolts securing the following to the engine block:

• | The left engine mount

• | The right engine mount

75. Position the engine mounts away from the engine.

Note: 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 radiator

• | The transmission input shaft (MA5 only)

• | The transmission oil cooler pipes (M30 only)

76. Carefully raise the engine from the engine compartment, ensuring the transmission stays supported.
77. If equipped with an automatic transmission, remove the automatic transmission flywheel locator. Refer to Flywheel Locator Removal.
78. Install the engine to an engine stand.
79. Remove the engine lift chain from the engine lift brackets.

### Installation Procedure

1. Install an engine lift chain to the engine lift brackets and attach to an engine lift devise.
2. Remove the engine from the engine stand.
3. If equipped with an automatic transmission, install the automatic transmission flywheel locator. Refer to Flywheel Locator Installation.
4. Ensure the torque converter is fully engaged with the transmission oil pump (M30 only).

Note: 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 radiator

• | The transmission input shaft (MA5 only)

• | The transmission oil cooler pipes (M30 only)

5. Carefully lower the engine into the engine compartment, aligning the engine dowels with the transmission.

Note: Ensure the torque converter turns freely while tightening the transmission mounting bolts (M30 only).

6. Align the engine dowels (1) with the transmission.
7. Loosely install the 2 transmission mounting bolts (2).

Ensure the dowels (1) are fully engaged into the transmission.

8. Remove the jack from under the vehicle.
9. Position the engine mounts to the engine.
10. Install the bolts securing the right engine mount to the engine block.

The engine lift devise may have to be raised or lowered slightly to install these bolts.

Caution: Refer to Fastener Caution in the Preface section.

11. To aid in the installation of the bolts, start bolt in this position (1) first.

Tighten the bolts to 50 N·m (37 lb ft).

12. Install the bolts securing the left engine mount to the engine block.

The engine lift devise may have to be raised or lowered slightly to install these bolts.

13. To aid in the installation of the bolts, start bolt in this position (1) first.

Tighten the bolts to 50 N·m (37 lb ft).

14. Lower the engine fully on to the engine mounts.
15. Remove the engine lift chain from the engine lift brackets.
16. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
17. Tighten the 2 transmission mounting bolts (2) previously installed to 50 N·m (37 lb ft).

Note:

• | Ensure the studded mounting bolts (2) are located in the correct position.

• | The heater pipe (1) must be secured with the 2 upper mounting bolts.

18. Install the remaining transmission mounting bolts and tighten to 50 N·m (37 lb ft).
19. Align the torque converter to flexplate/flywheel orientation marks made during the removal procedure (M30 only).
20. Repeat the following steps for all 3 torque converter bolts (M30 only):

20.1. | Rotate the harmonic balancer center bolt clockwise ONLY, in order to access the torque converter bolt holes in the flexplate/flywheel through the service slot.

20.2. | To aid in alignment of the torque converter to the flexplate/flywheel, install all 3 torque converter bolts before fully tightening using one of the following:

• | 18 mm crowfoot wrench

• | Short T50 TORX bit

• | Tighten the bolts to 60 N·m (44 lb ft).

21. Install the inspection plug (3) to the transmission (1) (M30 only).
22. Install the bolt (2) securing the transmission oil cooler pipe bracket to the right side of the engine oil pan rail (M30 only).

Tighten the bolt to 20 N·m (15 lb ft).

23. Install the exhaust seal. Refer to Exhaust Seal Replacement.
24. Install the service slot plug.
25. Install the applicable components:

• | RWD

• | Install the crossmember. Refer to Transmission Support Crossmember Replacement.

• | 4WD

1. | Position the differential carrier assembly to the frame.

2. | Install the differential carrier assembly bushing to frame bolts and tighten to 152 N·m (112 lb ft).

3. | Install the front propeller shaft. Refer to Front Propeller Shaft Replacement.

26. Install the nuts (2) securing the fuel hose/pipe bracket (1) to the transmission (M30 only).

Tighten the nuts to 20 N·m (15 lb ft).

27. Connect the fuel hose/pipe retainer (4) to the range selector cable bracket (3) (M30 only).
28. Install the nuts securing the fuel hose/pipe brackets to the transmission (MA5 only).

Tighten the nuts to 20 N·m (15 lb ft).

29. Install the left engine mount-to-frame bracket bolt and tighten to 85 N·m (63 lb ft).
30. Connect the engine wiring harness retainer (5) to the engine oil pan rail.
31. Install the 3 bolts securing the engine wiring ground leads (2) to the engine block.

Tighten the bolts to 20 N·m (15 lb ft).

32. Lower the vehicle to chest level in order to access the components through the wheelhouse.
33. Connect the engine wiring harness connector (3) to the CKP sensor (1).
34. Position the J 38185 (2) to the clamp (1) in order to connect the heater outlet hose to the heater outlet hose fitting (3).
35. Install the bolt (5) securing the heater outlet hose/pipe to the left engine mount (4).

Tighten the bolt to 9 N·m (80 lb in).

36. Connect the engine wiring harness retainer (4) to the engine oil pan rail.
37. Connect the engine wiring harness connector to the KS 1 (2).
38. Connect the engine wiring harness connector (3) to the KS 2 (1).
39. Connect the coolant heater cord to the coolant heater, if equipped.
40. Connect the engine wiring harness connector to the EVAP canister purge solenoid valve.
41. Install the bolt (4) securing the battery negative cable (5) to the engine block (1).

Tighten the bolt to 35 N·m (26 lb ft).

42. Connect the battery positive cable (2) to the starter and install the starter terminal nut (1).

Tighten the nut to 9 N·m (80 lb in).

43. Connect the lead (4) to the starter solenoid and install the starter solenoid "S" terminal nut (3).

Tighten the nut to 3.5 N·m (31 lb in).

44. Secure the following wiring harness retainers to the engine wiring harness bracket:

• | The battery cable

• | The engine (4, 6)

• | The MAP sensor (5)

45. Lower the vehicle.
46. Connect the MAP sensor wiring harness retainer (4) to the intake manifold (5).
47. Install the MAP sensor. Refer to Manifold Absolute Pressure Sensor Replacement.
48. Connect the brake booster hose (6) to the brake booster.
49. Install the oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement.
50. Connect the evaporative emission EVAP pipe at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service.
51. Connect the fuel feed pipe to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service.
52. Connect the engine wiring harness retainer (1) to the intake manifold (2).
53. Install the right engine mount-to-frame bracket bolt and tighten to 85 N·m (63 lb ft).
54. Position the power steering pump to the power steering pump bracket.
55. Install the power steering pump mounting bolts and tighten to 25 N·m (18 lb ft).
56. Connect the inlet heater hose quick connect (1) to the heater core (2).
57. Remove the J 44220 from the cylinder head.
58. Position the AIR pipe cover and NEW gasket to the cylinder head.
59. Install the AIR pipe cover studs and tighten to 25 N·m (18 lb ft).
60. Install the transmission filler tube (M30 only). Refer to Transmission Fluid Filler Tube and Seal Replacement.
61. Engage the engine wiring harness conduit to the camshaft cover.
62. Connect the engine wiring harness connector to the Intake CMP sensor.
63. Connect the engine wiring harness retainer (3) to the camshaft cover (4).
64. Connect the engine wiring harness connector (2) to the throttle body (1).
65. Connect the engine wiring harness electrical connectors to the ignition coils.
66. Connect the engine wiring harness connectors to the following components:

• | The fuel injector harness (1)

• | The HO2S (2)

• | The ECT sensor (3)

67. Connect the engine wiring harness retainer (2) to the camshaft cover (3).
68. Connect the engine wiring harness connectors to the following components:

• | The exhaust CMP sensor (5)

• | The exhaust camshaft actuator (6)

69. Connect the engine wiring harness retainers (1) to the power steering pump (2).
70. Connect the engine wiring harness connectors to the following components:

• | The electric motor actuator connector (4WD only)

• | The oil pressure switch

71. Connect the engine wiring harness retainers (1) to the wheelhouse (4).
72. Close the engine wiring harness retainer (5).
73. Connect the 2 engine wiring harness connectors (2) to the PCM (3).
74. Install the washer solvent container/coolant recovery reservoir mounting bolts. Refer to Windshield Washer Solvent Container Replacement.
75. Position the J 38185 to the clamp (3) in order to connect the radiator inlet hose (2) to the water outlet housing (4).
76. Install the generator. Refer to Generator Replacement.
77. Install the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement.
78. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
79. Install the cooling fan. Refer to Fan Replacement.
80. Install the outlet radiator hose. Radiator Outlet Hose Replacement.
81. Fill the cooling system. Refer to Cooling System Draining and Filling.
82. Install the battery box. Refer to Battery Box Replacement.
83. Install the hood. Refer to Hood Replacement.
84. Fill the engine oil, if previously drained. Refer to Engine Oil and Oil Filter Replacement.

### Engine Final Test and Inspection

Complete the following procedure after the engine is installed in the vehicle:

1. With the ignition OFF or disconnected, crank the engine several times. Listen for any unusual noises or evidence that any parts are binding.
2. Start the engine and listen for abnormal conditions.
3. Check the vehicle oil pressure gage or light and confirm that the engine has acceptable oil pressure.
4. Run the engine at approximately 1,000 RPM until the engine reaches normal operating temperature.
5. While the engine continues to idle raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
6. Inspect for oil, coolant, transmission fluid, and exhaust leaks while the engine is idling.
7. Lower the vehicle.
8. Perform the CKP variation learn procedure. Refer to Crankshaft Position System Variation Learn.
9. Perform a final inspection for the proper engine oil, transmission fluid and coolant levels.
10. Road test the vehicle.