Special Tools

1. Center the steering wheel.
2. Turn the ignition OFF.



3. Install the J 42640 to the steering column.



4. Disconnect the battery negative cable from the battery and the body. Refer to Battery Positive Cable Replacement .
5. Disconnect the battery positive cable from the battery and the underhood electrical center. Refer to Battery Positive Cable Replacement .
6. Position and secure the battery cables to the engine.
7. Remove the battery. Refer to Battery Replacement .
8. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
9. Remove the air cleaner duct. Refer to Air Cleaner Inlet Duct Replacement .
10. Drain the cooling system. Refer to Cooling System Draining and Filling .
11. Disconnect the overflow hose.
12. Position and secure the overflow hose to the engine.

Position and secure the overflow hose to the vehicle.

13. Disconnect the heater hoses from the heater core. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement .



14. Disconnect the purge line (3) from the purge solenoid.

Important: Plug the fuel pipe and cap the fuel rail to prevent fuel loss and/or contamination.

15. Disconnect the fuel pipe (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
16. Evacuate the air conditioning system. Refer to Refrigerant Recovery and Recharging .
17. Remove the A/C lines from the A/C compressor. Refer to Compressor Hose Assembly Replacement .



18. Disconnect the brake booster check valve and vacuum hose (1) from the brake booster (2).

Position and secure the brake booster hose to the engine.

19. Disconnect the brake fluid level switch electrical connector from the master cylinder.
20. Disconnect the mass air flow sensor electrical connector.
21. Unlock and disconnect the instrument panel (I/P) electrical connector from the engine.

Position and secure the I/P harness to the vehicle.

22. Disconnect the engine module wiring harness connectors.
23. Disconnect the wiring harness from the transmission control module (TCM). Refer to Transmission Control Module Replacement .




Important: Do NOT disconnect the brake pipes from the master cylinder.

24. Remove the master cylinder and reposition and secure the master cylinder to the engine.
25. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
26. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
27. Remove the catalytic converter. Refer to Catalytic Converter Replacement .
28. Remove the air deflector.
29. Disconnect the left front brake pipe retainer with the brake pipe.
30. Remove the right front brake pipe from the brake pipe.

Important: Cap and/or plug the brake pipes and the brake pressure modulator valve (BPMV) in order to minimize brake fluid loss.

31. Disconnect the rear brake pipes (two center pipes) from the BPMV. Refer to Electronic Brake Control Module Replacement .
32. Remove the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
33. Remove the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement .
34. Disconnect the transmission shift linkage from the transmission. Refer to Range Selector Lever Cable Replacement .




Important: Secure the shock modules to the lower control arms with a suitable strap in order to prevent damage to the front brake hoses.

35. Remove the right and left shock module upper mounting bolts. Refer to Strut Assembly Replacement .
36. Raise the vehicle enough to place a suitable lift table under the engine, transmission, front frame and front suspension assembly.
37. Position a suitable powertrain and/or engine lift table below the frame, engine and transmission.
38. Raise the lift table and/or lower the vehicle to support the frame, engine and transmission.
39. Remove the transmission brace to underbody bolts. Refer to Transmission Brace Replacement .
40. Remove the front frame bolts.

Important: Ensure that all the hoses, wires, pipes and shock modules clear the vehicle during the removal process.

41. With the aid of an assistant, lower the table and/or raise the vehicle to remove the engine, transmission, front frame and front suspension assembly from the vehicle.
42. Disconnect the engine control module (ECM) electrical connector. Refer to Engine Control Module Replacement .
43. Remove the thermostat housing with the heater pipes, heater hoses and surge tank outlet hose. Refer to Engine Coolant Thermostat Housing Replacement .
44. Remove the starter motor. Refer to Starter Motor Replacement .
45. Remove the heated oxygen sensor (HO2S) connectors.
46. Disconnect the transmission oil cooler (TOC) pipes from the engine, radiator and the transmission. Refer to Automatic Transmission Oil Cooler Hose Replacement .
47. Disconnect the radiator hoses from the water outlet housing and the coolant inlet pipe.
48. Cap and plug the power steering hoses and pipes in order to prevent fluid loss and contamination.
49. Remove the radiator hoses. Refer to Radiator Inlet Hose Replacement and Radiator Outlet Hose Replacement .
50. Install the EN 46114 to the engine.
51. Connect a floor crane to the engine lift brackets and raise the floor crane to partially support the engine.
52. Position a second powertrain lift table below the transmission.
53. Remove the transmission. Refer to Transmission Replacement .
54. Remove the drive belts. Refer to Drive Belt Replacement .
55. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Removal .
56. Remove the idler pulley. Refer to Drive Belt Idler Pulley Removal .
57. Remove the generator. Refer to Generator Replacement .
58. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement .
59. Remove the power steering pump. Refer to Power Steering Pump Replacement .
60. Remove the oil level indicator. Refer to Oil Level Indicator and Tube Removal .
61. Remove the left exhaust manifold. Refer to Exhaust Manifold Removal - Left Side .
62. Remove the oil filter adapter. Refer to Oil Filter Adapter Removal .
63. Remove the right exhaust manifold. Refer to Exhaust Manifold Removal - Right Side .
64. Remove the crankshaft balancer. Refer to Crankshaft Balancer Removal .
65. Remove the flywheel. Refer to Engine Flywheel Removal .
66. Remove the intake manifold. Refer to Intake Manifold Removal .
67. Remove the water outlet. Refer to Water Outlet Removal .
68. Remove the block heater. Refer to Coolant Heater Replacement .
69. Remove the ECM with the ECM bracket. Refer to Engine Control Module Replacement .
70. Use a floor crane in order to remove the engine from the frame.
71. Remove the engine mount brackets with the engine mounts.

1. Install the engine mount brackets with the engine mounts.
2. Use a floor crane in order to install the engine to the frame.
3. Install the ECM with the ECM bracket. Refer to Engine Control Module Replacement .
4. Install the water outlet. Refer to Water Outlet Removal .
5. Install the block heater. Refer to Coolant Heater Replacement .
6. Install the flywheel. Refer to Engine Flywheel Installation .
7. Install the intake manifold. Refer to Intake Manifold Installation .
8. Install the crankshaft balancer. Refer to Crankshaft Balancer Installation .
9. Install the right exhaust manifold. Refer to Exhaust Manifold Installation - Right Side .
10. Install the oil filter adapter. Refer to Oil Filter Adapter Installation .
11. Install the left exhaust manifold. Refer to Exhaust Manifold Installation - Left Side .
12. Install the oil level indicator. Refer to Oil Level Indicator and Tube Installation .
13. Install the generator and the generator bracket. Refer to Generator Replacement .
14. Install the power steering pump. Refer to Power Steering Pump Replacement .
15. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement .
16. Install the idler pulley. Refer to Drive Belt Idler Pulley Installation .
17. Install the drive belt tensioner. Refer to Drive Belt Tensioner Installation and Drive Belt Replacement .
18. Install the drive belts. Refer to Drive Belt Replacement .
19. Install the transmission-to-engine and flywheel-to-torque convertor bolts. Refer to Transmission Replacement .
20. Install the starter motor. Refer to Starter Motor Replacement .
21. Remove the EN 46114 from the engine.
22. Connect the radiator hoses to the water outlet housing and the coolant inlet pipe. Refer to Radiator Inlet Hose Replacement and Radiator Outlet Hose Replacement .
23. Install the TOC pipes to the engine, radiator and the transmission. Refer to Automatic Transmission Oil Cooler Hose Replacement .
24. Install the engine wiring harness and related components.
25. Install the HO2S connectors.
26. Install the thermostat housing with the heater pipes, heater hoses and surge tank outlet hose. Refer to Engine Coolant Thermostat Housing Replacement .
27. Install the catalytic converters with the oxygen sensors. Refer to Catalytic Converter Replacement .



28. Remove the cap or plug from the fuel line.
29. Install the fuel lines to the fuel rail and the EVAP purge solenoid. Refer to Metal Collar Quick Connect Fitting Service .
30. Install the purge line (3) to the purge solenoid.
31. Connect the ECM electrical connector. Refer to Engine Control Module Replacement .

Important: Ensure that all the hoses, wires, pipes and shock modules clear the vehicle during the installation process.

32. With the aid of an assistant, raise the table and/or lift the vehicle to install the engine, transmission, front frame and front suspension assembly to the vehicle.



33. Install the front frame bolts.
34. Install the transmission support to underbody bolts. Refer to Transmission Brace Replacement .
35. Remove the powertrain lift/support table.



36. Install the right and left shock module upper mounting bolts. Refer to Strut Assembly Replacement .
37. Connect the transmission shift linkage to the transmission. Refer to Range Selector Lever Cable Replacement .
38. Install the intermediate steering shaft . Refer to Intermediate Steering Shaft Replacement .
39. Install the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
40. Install the front brake pipes and retainers to the underbody.
41. Connect the rear brake pipes (two center pipes) to the BPMV. Refer to Electronic Brake Control Module Replacement .
42. Connect the radiator side air baffles to the radiator.
43. Install the air deflector.



44. Install the master cylinder.
45. Connect the engine harness electrical connector at the frame.

Notice: Refer to Fastener Notice in the Preface section.




46. Install the ground wire and bolt to the frame.

Tighten
Tighten the engine harness ground wire to longitudinal rail bolt to 10 N·m (89 lb in).

47. Connect the wiring harness to the TCM. Refer to Transmission Control Module Replacement .
48. Connect the engine module wiring harness connectors.
49. Connect and lock the I/P electrical connector.
50. Connect the mass air flow sensor electrical connector.
51. Connect the brake fluid level switch electrical connector from the master cylinder.



52. Connect the brake booster vacuum hose (1) to the brake booster (2).



53. Connect the purge line (3) to the purge solenoid.
54. Connect the fuel pipe (2) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
55. Connect the heater hoses to the heater core. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement .
56. Connect the overflow hose to the coolant overflow tank.
57. Connect the air conditioning pressure switch electrical connector and the liquid line to the evaporator.
58. Connect the air conditioning suction hose to the evaporator and install the suction hose bracket to the shock tower.
59. Install the air cleaner duct. Refer to Air Cleaner Inlet Duct Replacement .
60. Install the battery. Refer to Battery Replacement .
61. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .



62. Connect the battery positive cable to the battery and the underhood electrical center. Refer to Battery Positive Cable Replacement .
63. Connect the battery negative cable from the battery and the body. Refer to Battery Negative Cable Replacement .



64. Remove the J 42640 from the steering column.
65. Fill the cooling system. Refer to Cooling System Draining and Filling .
66. Charge the air conditioning system. Refer to Refrigerant Recovery and Recharging .
67. Bleed the brake system. Refer to Antilock Brake System Automated Bleed Procedure .