Aurora 2001-2003

Engine

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Removal & Installation



3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the crankcase and cooling system.
  4.  
  5. Recover the air conditioning system refrigerant.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Vacuum brake booster hose from the vacuum brake booster and secure to the top of the engine
     
    Fuel inlet and return quick-connect fittings at the fuel rail and secure to the air inlet grille
     
    Hose from the evaporative emission canister purge valve and secure to the air inlet grille
     
    Air cleaner assembly
     
    2 fuel injector sight shield nuts at the front of the fuel injector sight shield
     
    Fuel injector sight shield (lift up) at the front and slide out of the engine bracket
     
    Battery positive cable from the remote positive terminal and secure to the top of the engine
     
    Secondary AIR relay from the relay bracket and secure to the top of the engine
     

  8.  
  9. Disconnect and secure the following wiring harness electrical connectors to the top of the engine:

    Powertrain Control Module (PCM)
     
    Connection C101
     
    Engine electrical harness
     

  10.  
  11. Remove or disconnect the following:
    CAUTION
    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. Also 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.


    NOTE
    Make sure the wheels of the vehicle are in the straight position ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly.



    Engine ground cable from the right side body frame rail
     



    Cruise control cable from the throttle body bracket and lever
     
    Accelerator control cable from the throttle body
     
    Transaxle range selector cable terminal from the transaxle manual shift lever pin
     
    Transaxle range selector cable from the bracket and position the cable aside
     
    Radiator inlet hose from the water housing crossover
     
    Radiator outlet hose from the thermostat housing
     
    Surge tank inlet hose from the surge tank
     
    Heater outlet hose from the thermostat housing
     
    Heater inlet hose from the water crossover
     
    Two master cylinder brake pipes from the Brake Pressure Modulator Valve (BPMV) and plug the lines
     
    Transaxle oil cooler pipe bracket bolt from the fan shroud
     
    Plastic cap off the transaxle oil cooler pipe quick connect fittings
     
    Upper and lower transaxle oil cooler pipes from the radiator
     

  12.  
  13. Lock the steering column by installing tool J42460 into the underside of the steering column.
    CAUTION
    Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or damage to the intermediate shaft. This damage may cause loss of steering control which could result in personal injury.



    Right and left side strut tower bolts
     
    Transaxle oil cooler pipe bracket bolt from the lower tie bar
     
    Exhaust manifold pipe
     
    Front wheels
     
    Front wheel speed sensor electrical leads from the frame rail
     
    Front air deflector
     
    Front fascia extensions
     
    Secondary AIR inlet hose from the secondary AIR pump
     
    2 nuts securing the front brake pipe frame brackets to the frame rails
     
    Front brake pipes from the retainers at the frame rails
     
    Front brake pipes away from the body frame rails by carefully pulling them
     
    2 rear brake pipes at the rear of the engine frame
     
    A/C pressure sensor
     
    A/C discharge hose from the compressor and secure to the cooling fan assembly
     
    A/C suction hose from the compressor and secure to the cooling fan assembly
     



    Intermediate shaft pinch bolt
     
    Steering gear from the intermediate shaft
     
    Post Heated Oxygen Sensor (HO 2 S) at the pigtail
     
    Torque converter cover
     
    Torque converter-to-flywheel bolts
     

  14.  
  15. Position a suitable powertrain support dolly under the engine frame and lower the vehicle onto the dolly,
  16.  
  17. If the powertrain support dolly is unavailable. Support the powertrain with 4 suitable jackstands. Place a 2 in x 4 in block of wood between the front of the engine oil pan and the engine frame.
  18.  
  19. Remove or disconnect the following:
    CAUTION
    To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed.



    Nut securing the right engine mount to the engine mount bracket
     
    Nut securing the left transaxle mount to the transaxle mount bracket
     

  20.  
  21. Secure the front hoist pads to the vehicle.

    6 frame to body mounting bolts (3).
     

  22.  
  23. Make clearance is maintained between the powertrain assembly and the following components:

    A/C accumulator hose
     
    A/C compressor hose
     
    Brake pipes
     
    Heater hoses
     
    Radiator hoses
     
    Wheel speed sensor leads
     
    Wiring harnesses
     

  24.  
  25. Carefully raise the vehicle in order to clear the supported engine/transaxle assembly.
  26.  
  27. Remove or disconnect the following:

    Secondary air injection crossover pipe/hose
     
    Engine wiring harness from the engine
     
    Power steering return hose from the power steering pump reservoir
     
    Power steering return hose retaining bolt from the cylinder head
     
    Power steering pressure hose from the power steering pump
     
    Bolt securing the power steering pressure hose to the secondary AIR valve bracket
     
    3 bolts securing the right engine mount bracket to the engine
     
    Right engine mount bracket
     
    Bolts securing the transaxle brace to the engine and transaxle
     

  28.  
  29. Attach an engine lift chain to the engine lift brackets, then attach the chain to an engine lift device.

    Nut securing the front engine mount to the front engine mount bracket
     
    Bolts attaching the engine to the transaxle
     
    Engine
     

  30.  

To install:

  1. Installation is the reverse of removal, please note the following torques:

    Engine-to-transaxle bolts to 55 ft. lbs. (75 Nm)
     
    Front engine mount-to-bracket nut to 41 ft. lbs. (55 Nm)
     
    Transaxle brace bolts to 37 ft. lbs. (50 Nm)
     
    Right engine mount bracket bolts to 44 ft. lbs. (60 Nm)
     
    Power steering pressure hose to power steering pump to 22 ft. lbs. (30 Nm)
     
    Power steering pressure hose retaining bolt to 80 inch lbs. (9 Nm)
     
    Power steering return hose retaining bolt to 13 ft. lbs. (17 Nm)
     
    Frame mounting bolts to 141 ft. lbs. (191 Nm)
     
    Engine mount nuts to 59 ft. lbs. (80 Nm)
     
    Flywheel-to-torque converter bolts to 48 ft. lbs. (65 Nm)
     
    Intermediate shaft to steering gear pinch bolt to 33 ft. lbs. (45 Nm)
     
    A/C hoses to 15 ft. lbs. (20 Nm)
     

  2.  
  3. Connect the battery negative cable.
  4.  
  5. Fill the engine with oil.
  6.  
  7. Fill the cooling system.
  8.  
  9. Bleed the brake system.
  10.  
  11. Recharge the A/C system.
  12.  
  13. Bleed the power steering system.
  14.  
  15. Check the wheel alignment.
  16.  
  17. 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.  
    3. Start the engine and listen for abnormal conditions.
    4.  
    5. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
    6.  
    7. Run the engine at approximately 1000 RPM until the engine reaches normal operating temperature.
    8.  
    9. While the engine continues to idle raise and support the vehicle.
    10.  
    11. Inspect for oil, coolant and exhaust leaks while the engine is idling.
    12.  
    13. Lower the vehicle.
    14.  
    15. Perform the Crankshaft Position (CKP) system variation learn procedure.
    16.  
    17. Perform a final inspection for the proper engine oil and coolant levels.
    18.  
    19. Road test the vehicle.
    20.  

  18.  

4.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the crankcase and cooling system.
  4.  
  5. Recover the air conditioning system refrigerant.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Vacuum brake booster hose from the vacuum brake booster
     
    Fuel inlet and return quick-connect fittings at the fuel rail and secure to the air inlet grille
     
    Hose from the evaporative emission canister purge valve and secure to the air inlet grille
     
    Air cleaner assembly
     
    2 fuel injector sight shield nuts at the front of the fuel injector sight shield
     
    Fuel injector sight shield (lift up) at the front and slide out of the engine bracket
     
    Battery positive cable from the remote positive terminal and secure to the top of the engine
     
    Secondary AIR relay from the relay bracket and secure to the top of the engine
     

  8.  
  9. Disconnect and secure the following wiring harness electrical connectors to the top of the engine:

    Powertrain control Module (PCM)
     
    Connection C101
     
    Engine electrical harness
     

  10.  
  11. Remove or disconnect the following:
    CAUTION
    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. Also 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.


    NOTE
    Make sure the wheels of the vehicle are in the straight position ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly.



    Engine ground cable from the right side body frame rail
     



    Cruise control cable from the throttle body bracket and lever
     
    Accelerator control cable from the throttle body
     
    Transaxle range selector cable terminal from the transaxle manual shift lever pin
     
    Transaxle range selector cable from the bracket and position the cable aside
     
    Radiator inlet hose from the water housing crossover
     
    Radiator outlet hose from the thermostat housing
     
    Surge tank inlet hose from the surge tank
     
    Heater hoses
     
    Two master cylinder brake pipes from the Brake Pressure Modulator Valve (BPMV) and plug the lines
     
    Transaxle oil cooler pipe bracket bolt from the fan shroud
     
    Plastic cap off the transaxle oil cooler pipe quick connect fittings
     
    Upper and lower transaxle oil cooler pipes from the radiator
     

  12.  
  13. Lock the steering column by installing tool J42460 into the underside of the steering column.
    CAUTION
    Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or damage to the intermediate shaft. This damage may cause loss of steering control which could result in personal injury.



    Right and left side strut tower bolts
     
    Exhaust manifold pipe
     
    Front wheels
     
    Front wheel speed sensor electrical leads from the frame rail
     
    Front air deflector
     
    Front fascia extensions
     
    Secondary AIR inlet hose from the secondary AIR pump
     
    2 nuts securing the front brake pipe frame brackets to the frame rails
     
    Front brake pipes from the retainers at the frame rails
     
    Front brake pipes away from the body frame rails by carefully pulling them
     
    2 rear brake pipes at the rear of the engine frame
     
    A/C pressure sensor
     
    A/C discharge hose from the compressor and secure to the cooling fan assembly
     
    A/C suction hose from the compressor and secure to the cooling fan assembly
     



    Intermediate shaft pinch bolt
     
    Steering gear from the intermediate shaft
     
    Post Heated Oxygen Sensor (HO 2 S) at the pigtail
     
    Brace between the engine oil pan and the transaxle case
     
    Torque converter cover
     
    Torque converter-to-flywheel bolts
     

  14.  
  15. Position a suitable powertrain support dolly under the engine frame and lower the vehicle onto the dolly,
  16.  
  17. If the powertrain support dolly is unavailable. Support the powertrain with 4 suitable jackstands. Place a 2 in. x 4 in. block of wood between the front of the engine oil pan and the engine frame.
  18.  
  19. Remove or disconnect the following:
    CAUTION
    To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed.



    Nut securing the right engine mount to the engine mount bracket
     
    Nut securing the left transaxle mount to the transaxle mount bracket
     

  20.  
  21. Secure the front hoist pads to the vehicle.

    6 frame to body mounting bolts (3).
     

  22.  
  23. Make clearance is maintained between the powertrain assembly and the following components:

    A/C accumulator hose
     
    A/C compressor hose
     
    Brake pipes
     
    Heater hoses
     
    Radiator hoses
     
    Wheel speed sensor leads
     
    Wiring harnesses
     

  24.  
  25. Carefully raise the vehicle in order to clear the supported engine/transaxle assembly.
  26.  
  27. Remove or disconnect the following:

    Heater pipes
     
    Intermediate hose from the secondary AIR valve at bank 2
     
    Nut securing the intermediate hose to the secondary AIR valve at bank 1
     
    Nut securing the coil cassette ground wire to the right cylinder head
     
    Engine wiring harness from the engine
     
    Power steering return hose from the power steering pump reservoir
     
    Power steering return hose retaining bolt from the cylinder head
     
    Power steering pressure hose from the power steering pump
     
    Bolt securing the power steering pressure hose to the to the right engine mount bracket
     
    Bolts securing the right engine mount bracket to the engine
     
    Right engine mount bracket
     
    Bolts/nuts securing the transaxle brace-s to the engine and transaxle
     

  28.  
  29. Attach an engine lift chain to the engine lift brackets, then attach the chain to an engine lift devise.

    Nut securing the front engine mount to the front engine mount bracket
     
    Bolts attaching the engine to the transaxle
     
    Engine
     

  30.  

To install:

  1. Installation is the reverse of removal, please note the following torques:

    Engine-to-transaxle bolts to 55 ft. lbs. (75 Nm)
     
    Front engine mount-to-bracket nut to 52 ft. lbs. (70 Nm)
     
    Transaxle brace bolts to 37 ft. lbs. (50 Nm)
     
    Right engine mount bracket bolts to 37 ft. lbs. (50 Nm)
     
    Power steering pressure hose to power steering pump to 22 ft. lbs. (30 Nm)
     
    Power steering pressure hose retaining bolt to 80 inch lbs. (9 Nm)
     
    Power steering return hose retaining bolt to 37 ft. lbs. (50 Nm)
     
    Frame mounting bolts to 141 ft. lbs. (191 Nm)
     
    Engine mount nuts to 59 ft. lbs. (80 Nm)
     
    Flywheel-to-torque converter bolts to 44 ft. lbs. (60 Nm)
     
    Intermediate shaft to steering gear pinch bolt to 33 ft. lbs. (45 Nm)
     
    A/C hoses to 15 ft. lbs. (20 Nm)
     

  2.  
  3. Connect the battery negative cable.
  4.  
  5. Fill the engine with oil.
  6.  
  7. Fill the cooling system.
  8.  
  9. Bleed the brake system.
  10.  
  11. Recharge the A/C system.
  12.  
  13. Bleed the power steering system.
  14.  
  15. Check the wheel alignment.
  16.  
  17. 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.  
    3. Start the engine and listen for abnormal conditions.
    4.  
    5. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
    6.  
    7. Run the engine at approximately 1000 RPM until the engine reaches normal operating temperature.
    8.  
    9. While the engine continues to idle raise and support the vehicle.
    10.  
    11. Inspect for oil, coolant and exhaust leaks while the engine is idling.
    12.  
    13. Lower the vehicle.
    14.  
    15. Perform the Crankshaft Position (CKP) system variation learn procedure.
    16.  
    17. Perform a final inspection for the proper engine oil and coolant levels.
    18.  
    19. Road test the vehicle.
    20.  

  18.  

 
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