Notice: If the engine is damaged internally and a new engine assembly is installed in the vehicle, ensure that all foreign material is flushed out of the cooling system. You must also flush out the oil cooler system. Failure to rid the oil cooler system of debris can result in engine damage.

Tool Required

J 41427 Engine Lift Bracket

1. Disconnect the battery negative cable. Refer to Battery Replacement in Engine Electrical.
2. Remove the hood. Refer to Hood Replacement in Body Front End.
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Remove the underbody shields, if equipped.
5. Remove the exhaust pipe from the exhaust manifolds. Refer to Catalytic Converter Replacement in Engine Exhaust.
6. Disconnect the engine oil cooler pipes (RWD vehicle). Refer to Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling.
7. Disconnect the remote oil filter adapter inlet and outlet hoses (Four Wheel Drive vehicle). Refer to Remote Oil Filter Adapter Pipe Replacement .



8. Remove the stud holding the starter wire harness and if equipped, transmission oil cooler lines.
9. Remove the starter. Refer to Starter Motor Replacement in Engine Electrical.



10. Remove the transmission cover.
11. Remove the transmission.

•	Refer to Transmission Replacement in Automatic Transmission - 4L60-E.

•	Refer to Transmission Replacement in Manual Transmission - NV 3500.




12. Remove the front engine mount through bolts.
13. Lower the vehicle.



14. Remove the PCV tube from the right valve rocker arm cover and the air cleaner outlet duct.
15. Remove the air cleaner outlet duct from the throttle body. Refer to Air Cleaner Outlet Duct Replacement in Engine Controls.

Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.

In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.
16. Remove the accelerator control cable. Refer to Accelerator Control Cable Replacement in Engine Controls.
17. Remove the cruise control cable, if equipped from the throttle shaft and the accelerator cable bracket. Refer to Cruise Control Cable Replacement in Cruise Control.
18. Remove the radiator. Refer to Radiator Replacement in Engine Cooling.
19. Remove the inlet and outlet radiator hoses from the engine. Refer to Radiator Hose Replacement in Engine Cooling.
20. Disconnect the heater hoses from the engine. Refer to Heater Hoses Replacement in Heating Ventilation and Air Conditioning.



21. Disconnect the power brake booster vacuum hose from the intake manifold.
22. Disconnect the vacuum hose for the A/C system, if equipped from the intake manifold.



23. Disconnect the following electrical connectors:

•	The A/C compressor clutch (1), if equipped

•	The A/c compressor cutoff switch (5), if equipped

•	The TP sensor (2)

•	The IAC valve motor (3)

•	The ECT sensor (4)




24. Disconnect the following electrical connectors:

•	The fuel meter body (1)

•	The EVAP canister purge solenoid (2)

•	The MAP sensor (3)




25. Disconnect the following electrical connectors:

•	The ICM (1)

•	The ignition coil (2)

•	The EGR solenoid (3)

•	The generator (4)




26. Disconnect the following electrical connectors:

•	The distributor (1)

•	The engine oil pressure sensor (2)

•	The KS sensor (3)




27. Disconnect the CKP sensor (2) electrical connector.
28. Remove the bolt and the battery negative cable (1).
29. Remove the engine wiring harness bracket bolt (3).
30. Remove the engine wiring harness clips from the front of the engine.
31. Remove the engine wiring harness clips from the brackets.
32. Move the engine wiring harness aside.
33. Remove the generator. Refer to Generator Replacement in Engine Electrical.



34. Remove the bolt holding the ground wires to the left cylinder head.
35. Remove the bolt holding the fuel pipe bracket to the rear of left cylinder head.



36. Remove the bolts holding the ground wires to the right cylinder head.



37. Remove the bolt holding the ground strap to the right cylinder head.



38. Remove the accelerator control cable bracket from the throttle body.
39. Remove the water pump pulley. Refer to Water Pump Replacement in Engine Cooling.
40. Remove the A/C compressor, if equipped. Refer to Air Conditioning Compressor Replacement in Heating Ventilation and Air Conditioning.



41. Remove the nut holding the AIR reactor pipe bracket to the front of the engine, if equipped.
42. Remove the nuts holding the power steering pump rear bracket to the engine.
43. Remove the power steering pump mounting bracket. Refer to Accessory Mounting Brackets Replacement .

•	The power steering pump can remain on the mounting bracket.

•	The hoses do not require removal.

•	Remove the three bolts and the nut.

•	Slide the mounting bracket off of the stud.

•	Secure the mounting bracket out of the way.

Notice: Remove the AIR pipes before engine removal. The AIR pipes can break or damage easily causing erratic engine operation.

44. Remove both of the secondary air injection (AIR) reactor pipes from the engine.

•	Refer to Secondary Air Injection Check Valve and Check Valve Pipe Replacement - Bank 1 in Engine Controls.

•	Refer to Secondary Air Injection Check Valve and Check Valve Pipe Replacement - Bank 2 in Engine Controls.

45. Remove the AIR shut-off valve and hoses. Refer to Secondary Air Injection Shutoff Valve Replacement in Engine Controls.
46. Remove the distributor cap. Refer to Distributor Replacement in Engine Electrical.
47. Disconnect the fuel pipes at the rear of the intake manifold. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.
48. Disconnect the EVAP canister purge solenoid valve pipe. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement in Engine Controls.
49. Remove the water outlet. Refer to Engine Coolant Thermostat Replacement in Engine Cooling.



50. Remove the spark plug wire harness retainer from the exhaust gas recirculation (EGR) valve inlet pipe.
51. Remove the clamp bolt for the EGR valve inlet pipe.
52. Remove the EGR valve inlet pipe from the intake and the exhaust manifolds.




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

53. Attach the J 41427 to the left front and the right rear intake manifold mounting bolts, using the following procedure:

53.1.

Remove the right rear lower intake manifold bolts.

53.2.

Install the J 41427 marked RIGHT REAR.

53.3.

Install the retaining bolts.

53.4.

Remove the left front lower intake manifold bolts.

53.5.

Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of the engine.

53.6.

Install the retaining bolts.

Tighten
Tighten the retaining bolts to 15 N·m (11 lb ft).

54. Attach a suitable lifting device to the engine lift brackets.
55. Remove the engine.

Notice: If the engine is damaged internally and a new engine assembly is installed in the vehicle, ensure that all foreign material is flushed out of the cooling system. You must also flush out the oil cooler system. Failure to rid the oil cooler system of debris can result in engine damage.

Tool Required

J 41427 Engine Lift Bracket

1. Install the engine into the vehicle.




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the engine mount through-bolts and nuts.

Tighten
Tighten the engine mount through-bolts or the nuts to the following:

•	Tighten the through-bolts to 74 N·m (55 lb ft)

•	Tighten the nuts to 63 N·m (46 lb ft)

3. Remove the J 41427 and the engine lifting device.
4. Apply threadlock to the threads of the lower intake manifold bolts.
5. Install the intake manifold bolts.

Tighten

1. Tighten the bolts the first pass to 3 N·m (27 lb in).
2. Tighten the bolts the first pass to 12 N·m (106 lb in).
3. Tighten the bolts the first pass to 15 N·m (11 lb ft).



6. Install the EGR valve inlet pipe to the intake manifold and the exhaust manifold.

Tighten

1. Tighten the EGR valve inlet pipe intake manifold nut to 25 N·m (18 lb ft).
2. Tighten the EGR valve inlet pipe exhaust manifold nut to 30 N·m (22 lb ft).
3. Tighten the EGR valve inlet pipe clamp bolt 25 N·m (18 lb ft).
7. Install the spark plug wire harness retainer on the EGR valve inlet pipe.
8. Install the water outlet. Refer to Engine Coolant Thermostat Replacement in Engine Cooling.
9. Connect the fuel pipes at the rear of the engine. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.
10. Install the distributor cap. Refer to Distributor Replacement in Engine Electrical.
11. Connect the EVAP canister purge solenoid valve pipe. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement in Engine Controls.
12. Install both of the AIR reactor pipes to the engine.

•	Refer to Secondary Air Injection Check Valve and Check Valve Pipe Replacement - Bank 1 in Engine Controls.

•	Refer to Secondary Air Injection Check Valve and Check Valve Pipe Replacement - Bank 2 in Engine Controls.

13. Install the AIR shut-off valve and hoses. Refer to Secondary Air Injection Shutoff Valve Replacement in Engine Controls.
14. Install the power steering pump mounting bracket. Refer to Accessory Mounting Brackets Replacement .



15. Install the nuts holding the power steering pump rear bracket to the engine.

Tighten
Tighten the power steering pump rear bracket nuts to 41 N·m (30 lb ft).

16. Install the nut holding the AIR reactor pipe bracket , if equipped to the stud on the front of the engine.

Tighten
Tighten the bolt to 41 N·m (30 lb ft).

17. Install the A/C compressor, if equipped. Refer to Air Conditioning Compressor Replacement in Heating Ventilation and Air Conditioning.
18. Install the water pump pulley. Refer to Water Pump Replacement in Engine Cooling.



19. Install the accelerator control cable bracket to the throttle body.

Tighten
Tighten the bolt to 9 N·m (80 lb in).




20. Install the bolt holding the ground wires to the left cylinder head.

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

21. Install the bolt holding the fuel pipe bracket to the rear of the left cylinder head.

Tighten
Tighten the fuel pipe bracket bolt to 30 N·m (22 lb ft).




22. Install the stud holding the ground wires to the right cylinder head.

Tighten
Tighten the ground wire stud to 35 N·m (26 lb ft).




23. Install the bolt and the ground strap to the rear of the right cylinder head.

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




24. Position the engine wiring harness.
25. Install the engine wiring harness clips to the brackets.
26. Install the engine wiring harness clips to the front of the engine.
27. Connect the CKP sensor electrical connector (2).
28. Instal the bolt and the battery negative cable (1).

Tighten
Tighten the bolt to 17 N·m (13 lb ft).

29. Instal the engine wiring harness bracket bolt (3) to the generator mounting bracket.

Tighten
Tighten the stud to 25 N·m (18 lb ft).

30. Install the generator. Refer to Generator Replacement in Engine Electrical.



31. Connect the following electrical connectors:

•	The distributor (1)

•	The engine oil pressure sensor (2)

•	The KS sensor (3)




32. Connect the following electrical connectors:

•	The A/C compressor clutch (1), if equipped

•	The A/c compressor cutoff switch (5), if equipped

•	The TP sensor (2)

•	The IAC valve motor (3)

•	The ECT sensor (4)




33. Connect the following electrical connectors:

•	The fuel meter body (1)

•	The EVAP canister purge solenoid (2)

•	The MAP sensor (3)




34. Connect the following electrical connectors:

•	The ICM (1)

•	The ignition coil (2)

•	The EGR solenoid (3)

•	The generator (4)




35. Connect the power brake booster vacuum hose to the intake manifold.
36. Connect the vacuum hose for the A/C system, if equipped.

Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.

In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.
37. Install a NEW accelerator control cable. Refer to Accelerator Control Cable Replacement in Engine Controls.
38. Install the cruise control cable, if equipped to the throttle shaft and the accelerator cable bracket. Refer to Cruise Control Cable Replacement in Cruise Controls.
39. Install the radiator. Refer to Radiator Replacement in Engine Cooling.
40. Install the inlet and outlet radiator hose to the engine. Refer to Radiator Hose Replacement in Engine Cooling.
41. Connect the heater hoses to the engine. Refer to Heater Hoses Replacement in Heating Ventilation and Air Conditioning.
42. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
43. Install the transmission.

•	Refer to Transmission Replacement in Automatic Transmission - 4L60-E.

•	Refer to Transmission Replacement in Manual Transmission - NV 3500.




44. Install the transmission cover.

Tighten
Tighten the nut to 12 N·m (106 lb in).

45. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.



46. Install the stud holding the bracket for the starter wiring harness and if equipped, the transmission oil cooler lines.

Tighten
Tighten the bracket stud to 9 N·m (80 lb in).

47. Connect the engine oil cooler pipes (RWD vehicle). Refer to Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling.
48. Connect the remote oil filter inlet and outlet hoses (Four Wheel Drive vehicle). Refer to Oil Filter Adapter Replacement .
49. Install the exhaust pipe to the exhaust manifolds. Refer to Catalytic Converter Replacement in Engine Exhaust.
50. Install a NEW oil filter. Refer to Engine Oil and Oil Filter Replacement .
51. Install the underbody shields, if equipped.
52. Lower the vehicle.



53. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement .
54. Fill the cooling system with coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
55. Connect the battery negative cable. Refer to Battery Replacement in Engine Electrical.
56. Install the air cleaner outlet duct from the throttle body. Refer to Air Cleaner Outlet Duct Replacement in Engine Controls.
57. Remove the PCV tube from the right valve rocker arm cover and the air cleaner outlet duct.
58. Recharge the air conditioning system, if equipped. Refer to Refrigerant Recovery and Recharging in Heating Ventilation and Air Conditioning.
59. Install the hood. Refer to Hood Replacement in Body Front End.
60. Operate and test the engine. Refer to Engine Set-Up and Testing .