Canyon, Colorado 2004-2005

Engine

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Removal & Installation



  1. Disconnect the battery cables and properly relieve the fuel system pressure.
  2.  
  3. Drain the engine cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Reinstall the engine lift bracket after removing the alternator. Tighten the bolts to 44 inch lbs. (5 Nm) and then retighten to 37 ft. lbs. (50 Nm).



    Hood
     
    Battery box
     
    Radiator hoses
     
    Cooling fan
     
    Air cleaner assembly
     
    Engine lifting bracket
     
    Alternator
     



    Washer reservoir bolts
     
    Engine wiring harness connector at PCM
     
    Wiring harness retainers at fender, power steering pump, throttle body and camshaft cover
     
    Oil pressure switch connector
     
    4WD motor connector, if equipped
     
    Camshaft Position (CMP) sensor connector
     
    Exhaust camshaft actuator connector
     
    Coolant temperature sensor connector
     
    Injector harness connector
     
    Ignition coil connectors
     
    Oxygen Sensor (O 2 S) connector
     
    Wiring harness conduit at camshaft cover
     
    Automatic transmission filler tube, if equipped
     
    Air injection pipe cover
     
    Install engine lifting eye in air pipe cover location
     
    Heater hoses from heater core
     
    A/C suction hose bracket
     
    Power steering pump bolts and position pump aside
     
    Right engine mount-to-frame bracket bolt
     
    Wiring harness retainer from intake manifold and position aside
     
    Fuel lines from fuel rail
     
    Evaporative pipe at intake manifold
     
    Dipstick and tube
     
    Brake booster hose
     
    Manifold Absolute Pressure (MAP) sensor
     
    MAP wiring harness retainer
     
    Upper 2 engine wiring harness bracket bolts
     
    Raise and support vehicle
     
    Left front wheel
     
    Left front fender inner liner
     
    Wiring harness retainers from engine wiring bracket
     
    Engine wiring harness bracket
     
    A/C compressor mounting bolts and position compressor aside
     
    Starter wiring
     
    Negative battery cable from block
     
    EVAP canister connector
     
    Knock sensor connectors
     
    Heater outlet hose
     
    Crankcase Position (CKP) sensor connector
     
    Engine wiring ground leads from block
     
    Engine wiring harness retainer at oil pan rail and position harness aside
     
    Catalytic converter
     
    Exhaust donut gasket
     
    Automatic transmission oil cooler and fuel line brackets, if equipped
     
    Left engine mount-to-frame bracket bolt
     
    On 2WD drive models, front crossmember
     
    On 4WD models, differential carrier
     
    On automatic transmission, torque converter bolts after marking torque converter-to-flexplate location
     
    Leave 2 upper transmission-to-engine bolts, but remove all other bolts
     

  8.  
  9. Lower the vehicle and place a transmission jack under the transmission
  10.  
  11. Remove the remaining transmission mounting bolts
  12.  
  13. Install a suitable lifting device to the engine.
  14.  
  15. Remove the engine mount bolts and carefully lift the engine from the vehicle. Pause several times while lifting the engine to make sure no wires or hoses have become snagged.
  16.  

To install:

  1. Carefully lower the engine into the vehicle and align the engine dowels with the transmission.
  2.  
  3. Install the engine mount bolts and tighten the bolts to 37 ft. lbs. (50 Nm).
  4.  
  5. Lower the engine onto the engine mounts.
  6.  
  7. Remove the engine lifting device.
  8.  
  9. Raise and support the vehicle.
  10.  
  11. Install the transmission-to-engine bolts and tighten the bolts to 37 ft. lbs. (50 Nm).
  12.  
  13. Remove the transmission jack.
  14.  
  15. Aligning the torque converter to the flexplate, install the bolts and tighten to 44 ft. lbs. (60 Nm).
  16.  
  17. On 2WD, install the crossmember and tighten the bolts to 44 ft. lbs. (60 Nm).
  18.  
  19. On 4WD, install the differential carrier.
  20.  
  21. Install or connect the following:

    Automatic transmission oil cooler and fuel line brackets, if equipped
     
    Left engine mount-to-frame bracket bolt and tighten to 63 ft. lbs. (85 Nm).
     
    New exhaust donut gasket
     
    Catalytic converter and tighten the bolts to 37 ft. lbs. (50 Nm).
     
    Engine wiring harness retainers at oil pan rail
     
    Engine wiring ground leads to block
     
    CKP sensor connector
     
    Heater outlet hose
     
    Knock sensor connectors
     
    EVAP canister connector
     
    Negative battery cable to block
     
    Starter wiring
     
    A/C compressor mounting bolts tighten the bolts to 37 ft. lbs. (50 Nm)
     
    Engine wiring harness bracket
     
    Wiring harness retainers from engine wiring bracket
     
    Left front fender inner liner
     
    Left front wheel
     
    Lower the vehicle
     
    Upper 2 engine wiring harness bracket bolts
     
    MAP wiring harness retainer
     
    MAP sensor
     
    Brake booster hose
     
    Dipstick and tube
     
    Wiring harness retainer to intake manifold
     
    Evaporative pipe at intake manifold
     
    Fuel lines to fuel rail
     
    Right engine mount-to-frame bracket bolt and tighten bolt to 63 ft. lbs. (85 Nm)
     
    Power steering pump
     
    A/C suction hose bracket
     
    Heater hoses from heater core
     
    Remove engine lifting eye in air pipe cover location
     
    Air injection pipe cover using new gasket
     
    Automatic transmission filler tube
     
    Wiring harness conduit at camshaft cover
     
    Wiring harness retainers at fender, power steering pump, throttle body and camshaft cover
     
    Coolant temperature sensor connector
     
    Injector harness connector
     
    Ignition coil connectors
     
    Oxygen Sensor (O 2 S) connector
     
    Exhaust camshaft actuator connector
     
    CMP sensor connector
     
    4WD motor connector, if equipped
     
    Oil pressure switch connector
     
    Engine wiring harness connector at PCM
     
    Washer reservoir bolts
     
    Alternator
     
    Engine lifting bracket
     
    Air cleaner
     
    Cooling fan
     
    Radiator hoses
     
    Battery box
     
    Hood
     

  22.  
  23. Check all powertrain fluid levels and add, as necessary. Be sure to properly fill the engine crankcase with clean engine oil.
  24.  
  25. Connect the battery cables and properly fill the engine cooling system.
  26.  
  27. Start and run the engine, then check for leaks.
  28.  

  1. Disconnect the battery cables and properly relieve the fuel system pressure.
  2.  
  3. Drain the engine cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Reinstall the engine lift bracket after removing the alternator. Tighten the bolts to 44 inch lbs. (5 Nm) and then retighten to 37 ft. lbs. (50 Nm).



    Hood
     
    Battery box
     
    Radiator hoses
     
    Cooling fan
     
    Air cleaner assembly
     
    Engine lifting bracket
     
    Alternator
     



    Washer reservoir bolts
     
    Engine wiring harness connector at PCM
     
    Wiring harness retainers at fender, power steering pump, throttle body and camshaft cover
     
    Oil pressure switch connector
     
    4WD motor connector, if equipped
     
    Camshaft Position (CMP) sensor connector
     
    Exhaust camshaft actuator connector
     
    Coolant temperature sensor connector
     
    Injector harness connector
     
    Ignition coil connectors
     
    Oxygen Sensor (O 2 S) connector
     
    Wiring harness conduit at camshaft cover
     
    Automatic transmission filler tube, if equipped
     
    Air injection pipe cover
     
    Install engine lifting eye in air pipe cover location
     
    Heater hoses from heater core
     
    A/C suction hose bracket
     
    Power steering pump bolts and position pump aside
     
    Right engine mount-to-frame bracket bolt
     
    Wiring harness retainer from intake manifold and position aside
     
    Fuel lines from fuel rail
     
    Evaporative pipe at intake manifold
     
    Dipstick and tube
     
    Brake booster hose
     
    Manifold Absolute Pressure (MAP) sensor
     
    MAP wiring harness retainer
     
    Upper 2 engine wiring harness bracket bolts
     
    Raise and support vehicle
     
    Left front wheel
     
    Left front fender inner liner
     
    Wiring harness retainers from engine wiring bracket
     
    Engine wiring harness bracket
     
    A/C compressor mounting bolts and position compressor aside
     
    Starter wiring
     
    Negative battery cable from block
     
    EVAP canister connector
     
    Knock sensor connectors
     
    Heater outlet hose
     
    Crankcase Position (CKP) sensor connector
     
    Engine wiring ground leads from block
     
    Engine wiring harness retainer at oil pan rail and position harness aside
     
    Catalytic converter
     
    Exhaust donut gasket
     
    Automatic transmission oil cooler and fuel line brackets, if equipped
     
    Left engine mount-to-frame bracket bolt
     
    On 2WD drive models, front crossmember
     
    On 4WD models, differential carrier
     
    On automatic transmission, torque converter bolts after marking torque converter-to-flexplate location
     
    Leave 2 upper transmission-to-engine bolts, but remove all other bolts
     

  8.  
  9. Lower the vehicle and place a transmission jack under the transmission
  10.  
  11. Remove the remaining transmission mounting bolts
  12.  
  13. Install a suitable lifting device to the engine.
  14.  
  15. Remove the engine mount bolts and carefully lift the engine from the vehicle. Pause several times while lifting the engine to make sure no wires or hoses have become snagged.
  16.  

To install:

  1. Carefully lower the engine into the vehicle and align the engine dowels with the transmission.
  2.  
  3. Install the engine mount bolts and tighten the bolts to 37 ft. lbs. (50 Nm).
  4.  
  5. Lower the engine onto the engine mounts.
  6.  
  7. Remove the engine lifting device.
  8.  
  9. Raise and support the vehicle.
  10.  
  11. Install the transmission-to-engine bolts and tighten the bolts to 37 ft. lbs. (50 Nm).
  12.  
  13. Remove the transmission jack.
  14.  
  15. Aligning the torque converter to the flexplate, install the bolts and tighten to 44 ft. lbs. (60 Nm).
  16.  
  17. On 2WD, install the crossmember and tighten the bolts to 44 ft. lbs. (60 Nm).
  18.  
  19. On 4WD, install the differential carrier.
  20.  
  21. Install or connect the following:

    Automatic transmission oil cooler and fuel line brackets, if equipped
     
    Left engine mount-to-frame bracket bolt and tighten to 63 ft. lbs. (85 Nm).
     
    New exhaust donut gasket
     
    Catalytic converter and tighten the bolts to 37 ft. lbs. (50 Nm).
     
    Engine wiring harness retainers at oil pan rail
     
    Engine wiring ground leads to block
     
    CKP sensor connector
     
    Heater outlet hose
     
    Knock sensor connectors
     
    EVAP canister connector
     
    Negative battery cable to block
     
    Starter wiring
     
    A/C compressor mounting bolts tighten the bolts to 37 ft. lbs. (50 Nm)
     
    Engine wiring harness bracket
     
    Wiring harness retainers from engine wiring bracket
     
    Left front fender inner liner
     
    Left front wheel
     
    Lower the vehicle
     
    Upper 2 engine wiring harness bracket bolts
     
    MAP wiring harness retainer
     
    MAP sensor
     
    Brake booster hose
     
    Dipstick and tube
     
    Wiring harness retainer to intake manifold
     
    Evaporative pipe at intake manifold
     
    Fuel lines to fuel rail
     
    Right engine mount-to-frame bracket bolt and tighten bolt to 63 ft. lbs. (85 Nm)
     
    Power steering pump
     
    A/C suction hose bracket
     
    Heater hoses from heater core
     
    Remove engine lifting eye in air pipe cover location
     
    Air injection pipe cover using new gasket
     
    Automatic transmission filler tube
     
    Wiring harness conduit at camshaft cover
     
    Wiring harness retainers at fender, power steering pump, throttle body and camshaft cover
     
    Coolant temperature sensor connector
     
    Injector harness connector
     
    Ignition coil connectors
     
    Oxygen Sensor (O 2 S) connector
     
    Exhaust camshaft actuator connector
     
    CMP sensor connector
     
    4WD motor connector, if equipped
     
    Oil pressure switch connector
     
    Engine wiring harness connector at PCM
     
    Washer reservoir bolts
     
    Alternator
     
    Engine lifting bracket
     
    Air cleaner
     
    Cooling fan
     
    Radiator hoses
     
    Battery box
     
    Hood
     

  22.  
  23. Check all powertrain fluid levels and add, as necessary. Be sure to properly fill the engine crankcase with clean engine oil.
  24.  
  25. Connect the battery cables and properly fill the engine cooling system.
  26.  
  27. Start and run the engine, then check for leaks.
  28.  

3.4L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Hood
     
    Cross vehicle brace
     
    Engine mount struts
     
    Drive belt
     
    Brake booster vacuum hose
     
    Heated Oxygen Sensor (HO 2 S) electrical connector
     
    Secondary Air Injection (AIR) check valve electrical connector
     
    Exhaust Gas Recirculation (EGR) valve electrical connector
     
    Evaporative Emissions (EVAP) canister purge solenoid valve electrical connector
     
    Throttle Position Sensor (TPS) electrical connector
     
    Idle Air Control (IAC) valve electrical connector
     
    Alternator electrical connector
     
    Ignition coil electrical connector
     
    Wiring harness grounds
     
    Two engine wiring harness connectors
     
    Lower radiator air baffle
     
    Engine splash shields
     
    Oil filter
     
    Vehicle Speed Sensor (VSS) electrical connector
     
    Oil level sensor electrical connector
     
    Oil pressure switch electrical connector
     
    Engine block heater (if equipped)
     
    Knock Sensor (KS) electrical connector
     
    Crankshaft Position (CKP) sensor
     
    A/C compressor electrical connector
     
    Catalytic converter
     
    Engine mount lower nuts
     
    Torque converter cover
     
    Starter motor
     
    A/C compressor without disconnecting the lines
     
    Torque converter bolts
     
    Transaxle brace
     
    Radiator outlet hose
     
    Accelerator and cruise control cables
     
    Vacuum hoses from the upper intake manifold
     
    Fuel feed and return hoses
     
    Power steering pump without disconnecting the hoses
     
    Heater inlet and outlet hoses
     
    Radiator inlet hose
     

  10.  
  11. Attach an engine lifting device.
  12.  
  13. Remove the transmission bolts.
  14.  
  15. Remove the engine from the vehicle.
  16.  

To install:

  1. Install or connect the following:
    NOTE
    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.



    Engine to the transaxle and torque the bolts to 55 ft. lbs. (75 Nm)
     
    Radiator inlet hose
     
    Heater inlet and outlet hoses
     
    Power steering pump and torque the bolts to 25 ft. lbs. (34 Nm)
     
    Fuel feed and return hoses
     
    Vacuum hoses to the upper intake manifold
     

  2.  
  3. Remove the trim panel under the left instrument panel and detach the throttle cable from the top of the pedal then squeeze the retainer and push the cable through the bulkhead to remove it.
  4.  
  5. Install or connect the following:

    New accelerator cable
     
    Cruise control cable
     
    Radiator outlet hose
     
    Transmission brace and torque the transmission bolts to 32 ft. lbs. (43 Nm) and the engine bolts to 46 ft. lbs. (63 Nm)
     
    Torque converter-to-flywheel bolts and torque them to 47 ft. lbs. (63 Nm)
     
    A/C compressor and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Starter motor and torque the bolts to 32 ft. lbs. (43 Nm)
     
    Torque converter cover and torque the bolts to 89 inch lbs. (10 Nm)
     
    Engine mount lower nuts and torque them to 32 ft. lbs. (43 Nm)
     
    Catalytic converter and torque the nuts to 24 ft. lbs. (32 Nm)
     
    New oil filter
     
    VSS electrical connector
     
    Oil level sensor electrical connector
     
    Oil pressure switch electrical connector
     
    Engine block heater electrical connector
     
    KS electrical connector
     
    HO 2 S electrical connector
     
    CKP sensor electrical connector
     
    A/C compressor electrical connector
     
    Wiring harness grounds
     
    Lower radiator air baffle and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Engine splash shield and torque the fasteners to 18 inch lbs. (2 Nm)
     
    AIR check valve solenoid electrical connector
     
    EGR valve electrical connector
     
    EVAP canister purge solenoid valve electrical connector
     
    TPS electrical connector
     
    IAC valve electrical connector
     
    Alternator electrical connector
     
    Ignition coil electrical connector
     
    Wiring harness grounds
     
    Engine wiring harness connectors
     
    Drive belt
     
    Engine mount strut and torque the bolt to 35 ft. lbs. (48 Nm)
     
    Throttle body air inlet duct
     
    Cross vehicle brace and torque the nuts to 29 ft. lbs. (40 Nm)
     
    Hood and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Negative battery cable
     

  6.  
  7. Fill the engine oil.
  8.  
  9. Fill the engine coolant.
  10.  
  11. Inspect the transmission fluid level and top off if necessary.
  12.  
  13. Turn the ignition to the ON position several times to pressurize the fuel system.
  14.  
  15. Start the engine and inspect for any leaks, repair if necessary.
  16.  
  17. Check and top off the fluid levels if required.
  18.  

3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the engine cooling system.
  8.  
  9. Remove or disconnect the following:
    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.



    Front wheels
     
    Lower air deflector
     
    Fuel injector sight shield
     
    Left diagonal brace
     
    Air cleaner assembly
     
    Radiator inlet hose
     
    Alternator
     
    Fuel lines from the rail and position
     
    Fuel vapor line
     
    Throttle and cruise cables with the mounting bracket from the throttle body
     
    Automatic range selector cable from the Park/Neutral Position (PNP) switch
     
    Vacuum brake booster hose from the booster
     
    Transaxle oil cooler lines from the radiator
     
    Heater hoses from the engine
     
    Right side AIR control valve, if equipped
     
    Upper engine electrical connectors, including grounds
     
    Lower AIR hose from the elbow, if equipped and discard the clamp
     
    Lower electrical connectors, including grounds and the harness retainer
     
    Fog lamp electrical connectors, if equipped
     
    Torque converter cover
     
    Starter
     
    Bolts attaching the engine flywheel to the torque converter
     
    Engine splash shields from the inner fender
     
    A/C compressor and position aside without disconnecting the lines
     
    Catalytic converter pipe from the rear exhaust manifold
     
    Bolts attaching the lower transaxle to the engine
     
    Connectors from the Wheel Speed Sensors, and unclip the harnesses from the lower control arms
     
    Drive axles from the steering knuckles
     



    Pinch bolt from the intermediate steering shaft
     
    Intermediate shaft from the steering gear
     
    Upper and lower engine wiring harnesses position them aside
     

  10.  
  11. Place a frame table under the engine/transaxle/frame. With an assistant, lower the vehicle to the frame table in order to support the engine/transaxle/frame.

    Bolts attaching the frame to the body
     
    Frame table with the engine/transaxle/frame from under the vehicle
     
    Power steering pump from the engine and lay the pump aside
     
    Secondary air injection check valve/pipe, if equipped
     
    Dipstick tube
     
    Exhaust manifolds and crossover pipe
     

  12.  
  13. Install an engine lifting device to the engine.

    Bolts attaching the engine mount bracket to the engine
     
    Transaxle brace
     
    Bolts attaching the upper transmission to the engine
     
    Engine from the transaxle/frame
     

  14.  

To install:

  1. Installation is the reverse of removal, please note the following torques:
  2.  
  3. Install or connect the following:

    Bolts attaching the transmission to the engine to 55 ft. lbs. (75 Nm)
     
    Frame bolts to 133 ft. lbs. (180 Nm)
     

  4.  
  5. Center the steering angle sensor.
  6.  
  7. Fill the engine with new oil.
    NOTE
    A filter change is recommended.

  8.  
  9. Fill the cooling system.
  10.  
  11. Perform the Crankshaft Position (CKP) system variation learn procedure.
  12.  
  13. Start the engine and check for leaks, repair if necessary.
  14.  

5.3L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine sight shield.
  6.  
  7. Evacuate the air conditioning (A/C) system and recover the refrigerant.
  8.  
  9. Remove the front tires and wheels.
  10.  
  11. Drain the cooling system.
  12.  
  13. Drain the engine oil.
  14.  
  15. Lower the vehicle.
  16.  
  17. Reposition the inlet hose clamp at the radiator.
  18.  
  19. Remove the inlet hose from the radiator.
  20.  
  21. Reposition the outlet hose clamp at the radiator.
  22.  
  23. Disengage the outlet hose clips from the fan shroud.
  24.  
  25. Remove the outlet hose from the radiator.
  26.  
  27. Remove the A/C compressor hose nut at the A/C receiver/dehydrator tube.
  28.  
  29. Remove the A/C compressor hose.
  30.  
  31. Remove the A/C compressor hose nut at the A/C condenser.
  32.  
  33. Remove the A/C compressor hose.
  34.  
  35. Remove the brake booster vacuum hose from the brake booster.
  36.  
  37. Remove the brake booster vacuum hose from the intake manifold.
  38.  
  39. Disconnect the engine harness electrical connectors from the instrument panel (I/P) harness electrical connectors.
  40.  
  41. Disconnect the brake fluid level switch electrical connector from the master cylinder.
  42.  
  43. Remove brake fluid from the master cylinder.
  44.  
  45. Disconnect the from brake pipe fittings from the master cylinder.
  46.  
  47. Disconnect the brake pipe fittings from the antilock brake (ABS) module.
  48.  
  49. Remove the master cylinder nuts.
  50.  
  51. Position the master cylinder to the engine. Hold the master cylinder in place using mechanic's wire.
  52.  
  53. Relieve the fuel system pressure.
  54.  
  55. Disconnect the fuel feed line from the fuel rail.
  56.  
  57. Disconnect the evaporative emission (EVAP) line from the purge solenoid.
  58.  
  59. Remove the right front fender diagonal brace.
  60.  
  61. Remove the underhood electrical center cover.
  62.  
  63. Loosen the 4 integral bolts attaching the fuse block. Reposition the fuse block.
  64.  
  65. Loosen the engine harness connector bolt. Remove the engine harness connector from the bracket.
  66.  
  67. Disconnect the camshaft position sensor lead.
  68.  
  69. Disconnect the engine harness electrical connector from the ABS module.
  70.  
  71. Disconnect the engine harness electrical connector from the electronic brake control module (EBCM).
  72.  
  73. Remove the air cleaner assembly.
  74.  
  75. Disconnect the following electrical connectors:

    Transmission control module (TCM)
     
    Engine control module (ECM)
     
    A/C pressure sensor
     

  76.  
  77. Disconnect the engine harness electrical connector from the crankshaft position (CKP) sensor harness.
  78.  
  79. Disconnect the engine harness electrical connector from the power steering gear harness.
  80.  
  81. Remove the clip attaching the power steering gear harness to the bracket.
  82.  
  83. Remove the shift cable clip.
  84.  
  85. Disconnect the shift cable from the transaxle selector lever stud.
  86.  
  87. Remove the shift cable from the bracket.
  88.  
  89. Remove the vehicle speed sensor (VSS) shield nut and bolt. Remove the shield.
  90.  
  91. Disconnect the engine harness electrical connector from the VSS.
  92.  
  93. Set all branches of the engine wiring harness on top of the engine.
  94.  
  95. Reposition the intermediate shaft lower boot.
  96.  
  97. Remove the intermediate shaft to steering gear bolt.
  98.  
  99. Separate the intermediate shaft from the steering gear.
  100.  
  101. Disconnect both front wheel speed sensors.
  102.  
  103. Unclip the ABS wire harness from the lower control arm.
  104.  
  105. Reposition the heater inlet and outlet hose clamps.
  106.  
  107. Remove the heater inlet and outlet hoses from the heater inlet/outlet pipe.
  108.  
  109. Raise and support the vehicle.
  110.  
  111. Disconnect the stabilizer links from the stabilizer shaft.
  112.  
  113. Disconnect the ball joints from the steering knuckles.
  114.  
  115. Disconnect the power steering pressure hose from the steering gear.
  116.  
  117. Disconnect the power steering pressure line clips from the frame.
  118.  
  119. Disconnect the outer tie rod ends from the steering knuckles.
  120.  
  121. Loosen the power steering hose clamp at the inlet pipe.
  122.  
  123. Remove the power steering hose from the inlet pipe.
  124.  
  125. Remove the left and right halfshafts from the transaxle.
  126.  
  127. Support the halfshafts using mechanic's wire.
  128.  
  129. Remove the transaxle oil cooler line bracket bolt/stud.
  130.  
  131. Disconnect the transaxle oil cooler lines from the transaxle.
  132.  
  133. Remove the positive battery cable nut from the starter.
  134.  
  135. Remove the cable terminal from the starter.
  136.  
  137. Remove the battery cable ground nut.
  138.  
  139. Remove the cable ground terminal from the stud.
  140.  
  141. Remove the battery cable retainers from the engine frame.
  142.  
  143. Disconnect the exhaust system.
  144.  
  145. Disconnect the O 2 sensor harness pigtail.
  146.  
  147. Remove the transaxle converter cover bolt/stud.
  148.  
  149. Remove the converter cover.
  150.  
  151. Remove the flywheel bolts.
  152.  
  153. Remove the front air deflectors.

    Click image to see an enlarged view

    Fig. Engine holding fixture J39580-5.3L engine

  154.  
  155. Raise the vehicle enough to place engine holding fixture J39580 under the engine, frame, and front suspension.
  156.  
  157. Support the rear of the vehicle with suitable jackstand.
  158.  
  159. Strap the front of the vehicle to the hoist.
  160.  
  161. Raise the engine holding fixture, or lower the vehicle to preload the weight of the engine, frame, and front suspension.
  162.  
  163. Remove the radiator to frame brackets.
  164.  
  165. Remove the engine frame front bolts.
  166.  
  167. Remove the engine frame rear bolts.
  168.  
  169. With the aid of an assistant, lower the engine holding fixture and/or raise the vehicle to remove the engine and the frame from the vehicle.
  170.  
  171. Ensure that all hoses, wires, and pipes clear the vehicle during the removal process.
  172.  
  173. Use a suitable engine lift to support the engine.
  174.  
  175. Remove the front engine mount to frame nuts.
  176.  
  177. Remove the rear engine mount to frame nuts.
  178.  
  179. Remove the transaxle to engine bolts and stud.
  180.  
  181. Separate the engine from the transaxle.
  182.  
  183. Using a suitable engine lift, remove the engine from the frame.
  184.  
  185. Install the engine onto a suitable engine stand.
  186.  

To install:

  1. Using a suitable engine lift, remove the engine from the engine stand.
  2.  
  3. Position and install the engine to the frame and the transaxle.
  4.  
  5. Install the transaxle to engine bolts and stud. Tighten the bolts/stud to 75 Nm (55 ft. lbs.).
  6.  
  7. Install the rear engine mount to frame nuts. Tighten the nuts to 37 ft. lbs. (50 Nm).
  8.  
  9. Install the front engine mount to frame nuts. Tighten the nuts to 37 ft. lbs. (50 Nm).
  10.  
  11. Ensure that all hoses, wires, and pipes clear the vehicle during the installation process.
  12.  
  13. With the aid of an assistant, raise the engine holding fixture and/or lower the vehicle to install the engine and frame to the vehicle.
  14.  
  15. Install the engine frame rear bolts. Tighten the bolts to 160 Nm (118 ft. lbs.).
  16.  
  17. Install the engine frame front bolts. Tighten the bolts to 145 Nm (107 ft. lbs.).
  18.  
  19. Install radiator to front frame brackets.
  20.  
  21. Lower the engine holding fixture or raise the vehicle to preload the weight of the engine, frame, and front suspension.
  22.  
  23. Remove the support from under the rear of the vehicle.
  24.  
  25. Raise the vehicle enough to remove the engine holding fixture from under the engine, frame, and front suspension.
  26.  
  27. Connect the exhaust system and connect the O 2 sensor harness pigtail.
  28.  
  29. Install the flywheel bolts. Tighten the bolts to 63 Nm (47 ft. lbs.).
  30.  
  31. Install the converter cover.
  32.  
  33. Install the transaxle converter cover bolt/stud. Tighten the bolt/stud to 89 inch lbs. (10 Nm).
  34.  
  35. Install the left and right halfshafts into the transaxle.
  36.  
  37. Install the battery cable retainers to the engine frame.
  38.  
  39. Install the front air deflector.
  40.  
  41. Install the cable ground terminal to the stud.
  42.  
  43. Install the battery cable ground nut. Tighten the nut to 22 ft. lbs. (30 Nm).
  44.  
  45. Install the cable terminal to the starter.
  46.  
  47. Install the positive battery cable nut to the starter. Tighten the nut to 89 inch lbs. (10 Nm).
  48.  
  49. Connect the transaxle oil cooler lines to the transaxle.
  50.  
  51. Install the transaxle oil cooler line bracket bolt/stud. Tighten the bolt/stud to 18 ft. lbs. (25 Nm).
  52.  
  53. Install the power steering hose to the inlet pipe.
  54.  
  55. Tighten the power steering hose clamp at the inlet pipe. Tighten the clamp to 6 Nm (53 inch lbs.).
  56.  
  57. Connect the power steering pipe to the steering gear.
  58.  
  59. Connect the power steering pipe to the frame clips.
  60.  
  61. Lower the vehicle.
  62.  
  63. Position and install the ball joint nuts.
  64.  
  65. Install the sway links to the stabilizer shaft.
  66.  
  67. Install the tie rod ends to the steering knuckles.
  68.  
  69. Connect the wheel speed sensor electrical connectors.
  70.  
  71. Connect the wheel speed sensor wiring harness to the lower control arm.
  72.  
  73. Install the heater inlet and outlet hoses to the heater inlet/outlet pipe.
  74.  
  75. Reposition the heater inlet and outlet hose clamps.
  76.  
  77. Install the intermediate shaft to the steering gear.
  78.  
  79. Install the intermediate shaft to steering gear bolt. Tighten the bolt to 48 Nm (35 ft. lbs.).
  80.  
  81. Position the intermediate shaft lower boot.
  82.  
  83. Route all branches of the engine wiring harness to their correct locations.
  84.  
  85. Connect the engine harness electrical connector to the VSS.
  86.  
  87. Install the VSS shield. Install the VSS shield nut and bolt. Tighten the bolt/nut to 18 ft. lbs. (25 Nm).
  88.  
  89. Install the shift cable to the bracket.
  90.  
  91. Connect the shift cable to the transaxle selector lever stud.
  92.  
  93. Install the shift cable clip.
  94.  
  95. Install the clip attaching the power steering gear harness to the bracket.
  96.  
  97. Connect the engine harness electrical connector to the CKP sensor harness.
  98.  
  99. Connect the engine harness electrical connector to the power steering gear harness.
  100.  
  101. Connect the camshaft position sensor lead to the sensor.
  102.  
  103. Connect the following electrical connectors:

    ECM
     
    TCM
     
    A/C pressure sensor
     

  104.  
  105. Install the air cleaner assembly.
  106.  
  107. Connect the engine harness electrical connector to the EBCM.
  108.  
  109. Connect the engine harness electrical connector to the ABS module.
  110.  
  111. Install the engine harness connector to the bracket. Tighten the engine harness connector bolt. Tighten the bolt to 89 inch lbs. (10 Nm).
  112.  
  113. Position the fuse block. Tighten the 4 integral bolts attaching the fuse block. Tighten the bolts to 89 inch lbs. (10 Nm).
  114.  
  115. Install the electrical center cover.
  116.  
  117. Connect the fuel feed line to the fuel rail.
  118.  
  119. Connect the EVAP line to the purge solenoid.
  120.  
  121. Remove the mechanic's wire holding the master cylinder. Position the master cylinder to the brake booster.
  122.  
  123. Install the master cylinder nuts. Tighten the nuts to 33 Nm (24 ft. lbs.).
  124.  
  125. Connect the brake pipe fittings to the ABS module. Tighten the fittings to 15 Nm (11 ft. lbs.).
  126.  
  127. Connect the from brake pipe fittings to the master cylinder. Tighten the fittings to 22 ft. lbs. (30 Nm).
  128.  
  129. Connect the brake fluid level switch electrical connector to the master cylinder.
  130.  
  131. Connect the engine harness electrical connectors to the I/P harness electrical connectors.
  132.  
  133. Install the brake booster vacuum hose to the intake manifold.
  134.  
  135. Install the brake booster vacuum hose to the brake booster.
  136.  
  137. Install the A/C compressor hose.
  138.  
  139. Install the A/C compressor hose nut at the A/C condenser. Tighten the nut to 16 Nm (12 ft. lbs.).
  140.  
  141. Install the A/C compressor hose.
  142.  
  143. Install the A/C compressor hose nut at the A/C receiver/dehydrator tube. Tighten the nut to 16 Nm (12 ft. lbs.).
  144.  
  145. Install the outlet hose to the radiator.
  146.  
  147. Connect the outlet hose clips to the fan shroud.
  148.  
  149. Reposition the outlet hose clamp at the radiator.
  150.  
  151. Install the inlet hose to the radiator.
  152.  
  153. Reposition the inlet hose clamp at the radiator.
  154.  
  155. Install the front tires and wheels.
  156.  
  157. Connect the negative battery cable.
  158.  
  159. Install the right fender diagonal brace.
  160.  
  161. Refill the engine with oil.
  162.  
  163. Recharge the A/C system.
  164.  
  165. Refill the cooling system.
  166.  
  167. Bleed the brake system.
  168.  
  169. Check the transaxle fluid level, add fluid if necessary.
  170.  
  171. Install the engine sight shield.
  172.  
  173. Run the engine and inspect for leaks.
  174.  

 
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