Land Rover 2000-05

Engine

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Coolant
     
    Fuel system pressure
     
    Engine oil and filter
     
    Radiator hoses
     
    Radiator
     
    Upper intake manifold and ignition coil assemblies
     
    Fuel supply and return lines from the fuel rail
     
    Auxiliary drive belt
     
    The 3 bolts securing the Active Cornering Enhancement (ACE) pump, then position it aside leaving the hoses attached.
     
    The 4 bolts securing the air conditioning compressor, and position it aside leaving the hoses attached.
     
    Power steering hoses from the pump
     
    Coolant hoses at the water pump and rail
     
    Bolt securing the coolant rail and position the rail aside
     
    Engine ground and power supply cables
     
    Starter wiring harness
     
    The 2 engine wiring harness connectors from the fuse box
     
    EVAP solenoid connector
     
    Nut mounting the engine harness ground-to-body and detach the engine harness-to-main harness connector.
     
    Right side interior kick panel
     
    The 5 connectors attaching the engine harness to the ECM
     

  4.  
  5. Release the engine wiring harness, pull it into the engine bay and coil on top of engine.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Remove the 3 bolts securing the oil cooler lines to the engine block.
  10.  
  11. Detach the engine oil cooler lines and tie the lines aside.
  12.  
  13. Disconnect the front exhaust pipes from the manifolds.
  14.  
  15. Remove the torque converter access plug, matchmark the torque converter-to-driveplate relationship, then remove the 4 bolts securing the torque converter to the driveplate.
  16.  
  17. Remove the 12 engine-to-transmission mounting bolts.
  18.  
  19. Attach suitable lifting equipment to the engine.
  20.  
  21. Remove the 4 nuts securing the engine mounts, raise the engine and remove the engine mounts.
  22.  
  23. Support the transmission on a jack.
  24.  
  25. Separate the engine from the transmission dowels.
  26.  
  27. With the aid of an assistant, remove the engine from the engine bay.
  28.  

To install:

  1. Clean the mating faces of the engine and transmission, dowel and dowel holes.
  2.  
  3. With the aid of an assistant, position the engine in the engine bay, align to gearbox and locate on dowels.
  4.  
  5. Install the engine-to-transmission bolts and tighten to 37 ft. lbs. (50 Nm).
  6.  
  7. Install the engine mounts and tighten the fasteners to 63 ft. lbs. (85 Nm).
  8.  
  9. Remove the engine lifting equipment.
  10.  
  11. Align the torque converter to the driveplate, install the bolts and tighten to 37 ft. lbs. (50 Nm).
  12.  
  13. Install or connect the following:

    Torque converter access plug
     
    Front exhaust pipes to the manifolds
     
    All electrical connectors and replace any ties.
     
    Power steering hoses and check the fluid level
     
    Coolant hoses
     
    Radiator
     
    Coolant
     
    Air conditioning compressor mounting bolts to 16 ft. lbs. (22 Nm)
     
    ACE pump mounting bolts to 16 ft. lbs. (22 Nm)
     
    Accessory drive belt
     
    Fuel supply and return lines to the fuel rail
     
    Ignition coils
     
    Spark plug wires
     
    Upper intake manifold
     
    Oil filter
     
    Engine oil
     
    Transmission fluid level
     
    Negative battery cable
     

  14.  


NOTE
The engine and transaxle are removed as an assembly.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the hood.
  4.  
  5. Remove the battery and battery box.
  6.  
  7. Drain the cooling system and engine oil.
  8.  
  9. Drain the transaxle fluid.
  10.  
  11. Release the fuel system pressure.
  12.  
  13. Remove or disconnect the following:

    Acoustic cover
     
    ECM
     
    Engine wiring harness connectors
     
    Air box
     
    Fuse box cover
     
    Battery and starter leads from the fuse box
     
    All wiring from the fuse box
     
    Engine ground strap
     
    Wiring from the starter
     
    Wiring from the transaxle
     
    Fuel line from the fuel rail
     
    Hose from the purge valve
     
    Throttle cable
     
    Heater hoses
     
    Radiator hoses
     
    All remaining wiring and hoses
     
    Front wheels
     
    Halfshaft hub nuts
     
    Front suspension rear beam
     
    Exhaust pipe from the manifold
     

  14.  
  15. Matchmark the driveshaft-to-IRD unit. Remove the 6 nuts and bolts and disconnect the driveshaft from the IRD. Tie it aside.
    WARNING
    Do not allow the driveshaft to hang. Damage to the Tripod joint will occur.

  16.  
  17. Drain the IRD fluid.
  18.  
  19. Remove the right and left splash shields.
  20.  
  21. Remove or disconnect the following:

    Clips securing the brake hoses to the struts
     
    ABS sensor wiring
     
    Track rod ball studs from the steering arms
     
    Halfshafts
     
    Selector lever from the gearbox
     
    Accessory drive belts
     
    A/C compressor and tie it out of the way
     

  22.  
  23. Attach an engine crane to the engine using an equalizer.
  24.  
  25. Raise the engine just far enough to take the weight off the mounts.
  26.  
  27. Remove the left side engine mount and left transaxle mount.
  28.  
  29. Secure a lifting bracket to the transaxle using the mount bolts.
  30.  
  31. Place a wood block on a jack and raise the transaxle just enough to take its weight. Unhook the chain from the rear engine lift bracket and hook it to the transaxle bracket.
  32.  
  33. Remove the right side engine brackets.
  34.  
  35. Disconnect the power steering pressure hose from the front plate and top arm.
  36.  
  37. Remove the top arm.
  38.  
  39. Remove the power steering pulley.
  40.  
  41. Remove the power steering pump and position it out of the way.
  42.  
  43. Lift the engine from the vehicle.
  44.  

To install:

  1. With assistance, raise engine and gearbox into engine compartment.
  2.  
  3. Position PAS pump to front mounting plate, fit and tighten bolts to 18 ft. lbs. (25 Nm).
  4.  
  5. Position PAS pump pulley, fit and tighten Torx® screws to 7 ft. lbs. (9 Nm).
  6.  
  7. Position top arm to engine mounting bracket and right side hydramount, fit and tighten bolts to 74 ft. lbs. (100 Nm).
  8.  
  9. Position PAS pipe support bracket to right side hydramount, fit and tighten nut to 63 ft. lbs. (85 Nm).
  10.  
  11. Place a wooden block on jack, position jack under gearbox and raise jack sufficient to support weight of gearbox. Release lifting hook from lifting bracket on gearbox and connect to rear engine lifting bracket.
  12.  
  13. Lower and remove jack supporting gearbox.
  14.  
  15. Remove bolts securing lifting bracket to gearbox and remove bracket.
  16.  
  17. Position left side mounting bracket to gearbox, fit and tighten bolts to 63 ft. lbs. (85 Nm).
  18.  
  19. Position left side mounting to body, fit and tighten bolts to 35 ft. lbs. (48 Nm).
  20.  
  21. Align gearbox bracket to left side body mounting, fit and tighten through bolt to 74 ft. lbs. (100 Nm).
  22.  
  23. Position upper right side engine steady to top arm, fit and tighten bolt to 74 ft. lbs. (100 Nm).
  24.  
  25. Tighten bolt securing upper right side engine steady to body to 74 ft. lbs. (100 Nm).
  26.  
  27. Position PAS pipe to engine front mounting plate, fit and tighten bolt to 18 ft. lbs. (25 Nm).
  28.  
  29. Lower hoist, disconnect and remove lifting bracket.
  30.  
  31. Raise vehicle on ramp.
  32.  
  33. Position A/C compressor to front mounting plate and cylinder block, align heat shield, fit and tighten bolts to 18 ft. lbs. (25 Nm).
  34.  
  35. Connect multiplug to A/C compressor.
  36.  
  37. Using a 3 / 8 square drive socket bar, raise auxiliary drive belt tensioner and fit drive belt to pulleys.
  38.  
  39. Position selector cable to gearbox bracket and secure with clip.
  40.  
  41. Position selector lever to selector shaft, fit and tighten nut to 18 ft. lbs. (25 Nm).
  42.  
  43. Clean splines and seal areas on each driveshaft and mating faces in front hubs.
  44.  
  45. Install new circlips to right side and left side driveshaft inner joint splines.
  46.  
  47. Install driveshafts to IRD and gearbox, ensuring that the circlip on each driveshaft is fully engaged.
  48.  
  49. Engage left side and right side driveshafts into front hubs.
  50.  
  51. Install new driveshaft flange nuts but do not tighten at this stage.
  52.  
  53. Clean ball joint tapers and taper seats.
  54.  
  55. Position left side and right side track rod ends to steering arms, fit new nuts and tighten to 40 ft. lbs. (55 Nm).
  56.  
  57. Clean ABS sensors and mating faces.
  58.  
  59. Apply anti-seize grease to both ABS sensors and position sensors in front hubs.
    NOTE
    Ensure ABS sensor is fully located into hub, so that sensor touches pole wheel teeth.

  60.  
  61. Position left side and right side brake hoses to front shock absorber brackets and secure with clips.
  62.  
  63. Position left side and right side splash shields, fit and tighten bolts.
  64.  
  65. Ensure mating face of propeller shaft and IRD drive flange are clean.
  66.  
  67. Install propeller shaft to IRD flange and align marks. Tighten nuts and bolts to 31 ft. lbs. (42 Nm).
  68.  
  69. Install rear beam.
  70.  
  71. Fill IRD to correct level with fluid.
  72.  
  73. Install exhaust front pipe.
  74.  
  75. With assistant depressing the brake pedal, tighten front hub nuts to 295 ft. lbs. (400 Nm).
  76.  
  77. Stake nut to shaft.
  78.  
  79. Install front wheels, fit and tighten nuts to 85 ft. lbs. (115 Nm).
  80.  
  81. Lower vehicle on ramp.
  82.  
  83. Connect brake servo vacuum hose to intake manifold chamber.
  84.  
  85. Connect coolant hose to underside of expansion tank and secure with clip.
  86.  
  87. Connect expansion tank hose to intake manifold and secure clip.
  88.  
  89. Connect top hose to radiator and secure with clip. Position hose in bracket.
  90.  
  91. Connect heater feed and return hoses and secure with clips.
  92.  
  93. Connect throttle inner cable to throttle cam and secure outer cable in abutment bracket, if equipped.
  94.  
  95. Secure throttle cable in clips on harness brackets, if equipped.
  96.  
  97. Adjust throttle cable, if equipped.
  98.  
  99. Connect hose to purge control valve.
  100.  
  101. Connect fuel hose to fuel rail pipe, fit rubber sleeve over hose connector.
  102.  
  103. Connect gearbox harness connectors and secure connectors in mounting bracket clips.
  104.  
  105. Connect Lucar connector to starter solenoid.
  106.  
  107. Position ground lead to gearbox housing, fit and tighten bolt to 18 ft. lbs. (25 Nm).
  108.  
  109. Position engine harness to air box mounting bracket and secure with clips.
  110.  
  111. Connect ground header connector.
  112.  
  113. Connect multiplug to underhood fuse box.
  114.  
  115. Position battery and starter motor lead to underhood fuse box, fit and tighten bolts to 6 ft. lbs. (8 Nm).
  116.  
  117. Install underhood fuse box cover.
  118.  
  119. Position air box, secure in retaining clip, fit and tighten nut to 7 ft. lbs. (9 Nm).
  120.  
  121. Position carrier in air box and secure with clips.
  122.  
  123. Position and secure air duct and harness rubber sleeve in air box.
  124.  
  125. Connect connectors securing main harness to engine harness.
  126.  
  127. Position ECM harness and multiplug to air box, align harness clamp and secure screws to air box.
  128.  
  129. Install engine ECM.
  130.  
  131. Install battery carrier.
  132.  
  133. Fill cooling system.
  134.  
  135. Connect the negative battery cable.
  136.  
  137. Fill gearbox with fluid.
  138.  
  139. Install engine acoustic cover.
  140.  


NOTE
The engine and automatic transaxle are removed as an assembly.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the battery ground.
  4.  
  5. Open the hood and tie it back in an upright position.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove the engine acoustic cover by releasing clips and retaining straps and disconnecting hoses.
  10.  
  11. Remove the battery and carrier.
  12.  
  13. Remove the ECM by removing electrical box cover and disconnecting plugs, releasing 2 clips and removing the ECM.
  14.  
  15. Remove the bolt retaining the heated front screen harness to the battery positive cable. Remove the clamp.
  16.  
  17. Disconnect the body harness from the engine harness at the electrical box. Move the harness aside.
  18.  
  19. Drain the transaxle fluid.
  20.  
  21. Mark and disconnect remaining connectors at electrical box. Release the air duct from the electrical box.
  22.  
  23. Rotate the heated front windshield relay counterclockwise and release it from the electrical box. Then remove the electrical box.

    Click image to see an enlarged view

    Fig. Removing heated front windshield relay-Freelander

  24.  
  25. Remove the engine compartment fuse box cover. Remove the 2 bolts holding the battery and starter leads to the fuse box.
  26.  
  27. Disconnect the multiplug connector from the fuse box.
  28.  
  29. Disconnect the ground multiplug from the shock tower, and release 3 clips holding the engine harness to the electrical box mounting bracket. Lay the harness over the engine.

    Click image to see an enlarged view

    Fig. Showing location of ground multiplug and engine harness clips-Freelander

  30.  
  31. Release the fuel system pressure.
  32.  
  33. Remove or disconnect the engine ground strap, starter solenoid connector, and the transmission harness multiplug connectors.
  34.  
  35. Position an absorbent cloth around the fuel pipe connections. Pull the back rubber sleeve on the fuel pipe connector. Release the connector and disconnect the fuel pipe from the fuel rail.
  36.  
  37. Remove or disconnect the following:

    Canister purge hose from clip and from purge control valve
     
    Heater hoses
     
    Upper radiator hose from radiator and retainers
     
    Expansion tank hose from intake manifold
     
    Hose from lower side of expansion tank
     
    Brake servo hose from intake manifold chamber, then plug openings
     

  38.  
  39. Raise the vehicle on a lift. Remove the front wheels.
  40.  
  41. Release the stake in the driveshaft (hub) nut, hold brake and remove and discard left and right driveshaft nuts.
  42.  
  43. Remove the front suspension rear crossmember by removing the under-vehicle panel, rear engine mount bolt, anti-roll bar clamp bolts (support anti-roll bar), lower control arm rear nuts and bushing housing bolts.
  44.  
  45. Release lower control arms from the crossmember. Support the crossmember and remove 2 remaining crossmember bolts. Remove crossmember.
  46.  
  47. Remove the front exhaust pipes from the manifolds.
  48.  
  49. In order to access the propeller shaft retaining bolts, raise one rear wheel for rotation of the propeller shaft.
  50.  
  51. Reference mark the position of coupling flange to Intermediate Reduction Drive (IRD) unit flange, then remove 6 nuts and bolts holding propeller shaft to IRD drive flange. Release propeller shaft and tie out of way.
    CAUTION
    Use care to support the U-joint when it is removed from the IRD drive flange coupling. Do not allow unit to fully extend or drop, or damage to boot or component will result.

  52.  
  53. Drain the transmission fluid. Drain the fluid from the IRD axle.
  54.  
  55. Remove the right and left splash shields.
  56.  
  57. Remove the clips securing the brake hoses to their brackets. Release the ABS sensor leads from the brackets. Remove the ABS sensors from the front hubs.
  58.  
  59. Separate the right and left ball joints from the steering arms.
  60.  
  61. Pull the right and left hubs outward and release the driveshafts from the hubs. Use care so driveshafts do not fall.
  62.  
  63. Using a special clamping tool (LRT-54-026), release the driveshafts from the IRD unit and transmission.

    Click image to see an enlarged view

    Fig. Releasing driveshafts from intermediate reduction drive unit-Freelander

  64.  
  65. Remove the selector lever from the selector shaft on the transmission. Release the cable-to-transmission clip. Move cable aside.
  66.  
  67. Release tension from the accessory drive belt tensioner by loosening the tensioner nut and moving the tensioner clockwise, then retighten the nut in this position.
  68.  
  69. Disconnect the connector from the A/C compressor. Remove compressor bolts and move the compressor aside, with the heat shield attached.
  70.  
  71. Lower the vehicle.
  72.  
  73. With a hoist and lifting bracket attached to engine, raise hoist to remove weight from engine mounts. Remove engine mount bolts.
  74.  
  75. Using transmission bracket bolts, attach transmission-lifting bracket (LRT-44-026). Position a transmission jack under the transmission to support its weight.
  76.  
  77. Release the lifting hook from the rear lift bracket and connect it to the transmission-lifting bracket.
  78.  
  79. Loosen bolts holding the upper left and right engine stays. Position the stay out of the way.
  80.  
  81. Remove or disconnect the following:

    Power steering pipe from engine front mounting plate
     
    Engine top arm bracket from right hydra-mount and front mounting bracket
     
    Power steering pipe support bracket from hydra-mount (position the pipe aside)
     
    Power steering pipe from engine front mounting plate
     
    Top arm
     
    Power steering pump from front mounting plate (position pump aside)
     

  82.  
  83. With an assistant, carefully lower engine and transmission assembly from the vehicle.
  84.  

To install:

  1. With an assistant, raise engine and transmission into engine compartment.
  2.  
  3. Position the power steering pump to its front mounting plate. Install and torque bolts to 18 ft. lbs. (25 Nm).
  4.  
  5. Install the top arm to the engine mounting bracket and right hydra-mount. Torque bolts to 74 ft. lbs. (100 Nm).
  6.  
  7. Install power steering pipe support bracket to right hydra-mount. Torque retaining nut to 63 ft. lbs. (85 Nm).
  8.  
  9. Place a transmission jack under the transmission and raise the jack enough to support the transmission weight. Release the lifting hook from the transmission-lifting bracket and connect it to the rear engine-lifting bracket.
  10.  
  11. Remove the transmission jack.
  12.  
  13. Remove the lifting bracket from the transmission.
  14.  
  15. Install the left transmission mount bracket. Torque bolts to 63 ft. lbs. (85 Nm).
  16.  
  17. Install the left mount to the body and torque bolts to 35 ft. lbs. (48 Nm).
  18.  
  19. Align the transmission mount bracket to the left body mount. Install and torque the bolt to 74 ft. lbs. (100 Nm).
  20.  
  21. Install the upper right engine stay to the top arm. Install and torque the bolt to 74 ft. lbs. (100 Nm).
  22.  
  23. Torque the bolt securing the upper right engine stay to body to 74 ft. lbs. (100 Nm).
  24.  
  25. Install the power steering pipe to the engine front mounting plate and torque the bolt to 18 ft. lbs. (25 Nm).
  26.  
  27. Lower the engine hoist to release pressure, then remove the lifting bracket.
  28.  
  29. Raise the vehicle on the lift.
  30.  
  31. Position the A/C compressor to the front mounting plate and cylinder block. Align the heat shift. Torque the retaining bolts to 18 ft. lbs. (25 Nm).
  32.  
  33. Clean the splines and seal areas on each driveshaft, and the mating faces in the front hubs. Install new circlips to the inner joint splines.
  34.  
  35. Install the driveshaft to the IRD unit and to the transmission. Be sure the circlip on each driveshaft is fully engaged.
  36.  
  37. Position the driveshafts into the front hubs. Install new driveshaft flange nuts, but do not tighten nuts at this stage.
  38.  
  39. Reconnect the ball joints and track rod ends to steering arms. Tighten new retaining nuts to 41 ft. lbs. (55 Nm).
  40.  
  41. Clean the ABS sensors and mating faces. Apply anti-seize grease to both sensors and position into the front hubs. Ensure both sensors are fully seated and touching the pole wheel teeth.
  42.  
  43. Reconnect the brake hoses to their brackets and clips. Install the splash shields.
  44.  
  45. Be sure the mating faces of the propeller shaft and IRD drive flange are clean. Position the shaft to the IRD flange and align the marks made during removal. Torque the retaining nuts and bolts to 31 ft. lbs. (41 Nm).
  46.  
  47. Install the rear crossmember in reverse of the removal procedure.
  48.  
  49. Fill the IRD unit with proper fluid.
  50.  
  51. Install the front exhaust pipes.
  52.  
  53. Have an assistant hold the brake pedal, then install the front hub nuts. Torque nuts to 295 ft. lbs. (400 Nm), and stake the nuts to the shaft.
  54.  
  55. Install front wheels and torque the wheel nuts to 85 ft. lbs. (115 Nm).
  56.  
  57. Lower the vehicle on the lift.
  58.  
  59. Reconnect or install the following:

    Brake servo vacuum hose to intake manifold chamber
     
    Coolant hoses to expansion tank
     
    Upper radiator hose
     
    Heater hoses
     
    Throttle inner cable to throttle cam and outer cable in bracket
     
    Canister purge hose
     
    Fuel hose to rail pipe, then rubber sleeve over hose connector
     
    Transmission electrical connectors
     
    Connector to starter solenoid
     
    Ground strap to transmission; torque bolt to 18 ft. lbs. (25 Nm)
     
    Engine harness to electrical box
     
    Multiplug to underhood fuse box
     
    Battery and starter motor led to underhood fuse box
     
    Fuse box cover
     
    Electrical box (E-box) and connectors
     
    Heated front screen harness to battery cable
     
    ECM
     
    Battery carrier
     

  60.  
  61. Refill cooling system.
  62.  
  63. Connect battery cables to battery.
  64.  
  65. Refill transmission.
  66.  
  67. Install engine sound shield.
  68.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    CAUTION
    Always plug any line or connections openings immediately.



    Negative battery cable
     
    Coolant
     
    Fuel system pressure
     
    Engine oil and filter
     
    Radiator hoses
     
    Radiator
     
    Upper intake manifold and ignition coil assemblies
     
    Fuel supply and return lines from the fuel rail
     
    Auxiliary drive belt
     
    The 3 bolts securing the Active Cornering Enhancement (ACE) pump, then position it aside leaving the hoses attached.
     
    Electrical connector and 4 bolts securing the air conditioning compressor, and position it aside leaving the hoses attached.
     



    Power steering hoses from the pump, then position hoses out of the way
     
    Coolant hoses at the water pump and rail
     
    Bolt and harness clips securing the coolant rail and position the rail aside
     
    Engine ground and power supply cables
     
    Starter wiring harness
     
    The 2 engine wiring harness connectors from the fuse box
     
    EVAP solenoid connector
     
    Nut mounting the engine harness ground-to-body and detach the engine harness-to-main harness connector.
     
    Right side interior kick panel
     
    The 5 connectors attaching the engine harness to the ECM
     

  4.  
  5. Release the engine wiring harness, pull it into the engine bay and coil on top of engine.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Remove the 3 bolts securing the oil cooler lines to the engine block.
  10.  
  11. Detach the engine oil cooler lines and tie the lines aside.
  12.  
  13. Disconnect the front exhaust pipes from the manifolds.
  14.  
  15. Remove the torque converter access plug, matchmark the torque converter-to-driveplate relationship, then remove the 4 bolts securing the torque converter to the driveplate.
  16.  
  17. Remove the 12 engine-to-transmission mounting bolts (rotating engine as needed for access).
  18.  
  19. Collect support brackets from bell housing.
  20.  
  21. Attach suitable lifting equipment to the engine.
  22.  
  23. Remove the 4 nuts securing the engine mounts, raise the engine and remove the engine mounts.
  24.  
  25. Support the transmission on a jack.
  26.  
  27. Separate the engine from the transmission dowels.
  28.  
  29. With the aid of an assistant, remove the engine from the engine bay.
  30.  

To install:

  1. Clean the mating faces of the engine and transmission, dowel and dowel holes.
  2.  
  3. Lubricate the splines and bearing surface of first motion shaft.
  4.  
  5. With the aid of an assistant, position the engine in the engine bay, align to gearbox and locate on dowels.
  6.  
  7. Install the engine-to-transmission bolts and tighten to 37 ft. lbs. (50 Nm).
  8.  
  9. Install the engine mounts and tighten the fasteners to 63 ft. lbs. (85 Nm).
  10.  
  11. Remove the engine lifting equipment.
  12.  
  13. Align the torque converter to the driveplate, install the bolts and tighten to 37 ft. lbs. (50 Nm).
  14.  
  15. Install or connect the following:

    Torque converter access plug
     
    Front exhaust pipes to the manifolds
     
    All electrical connectors and replace any ties.
     
    Power steering hoses and check the fluid level
     
    Coolant hoses
     
    Radiator
     
    Coolant
     
    Air conditioning compressor mounting bolts to 16 ft. lbs. (22 Nm)
     
    ACE pump mounting bolts to 16 ft. lbs. (22 Nm)
     
    Accessory drive belt
     
    Fuel supply and return lines to the fuel rail
     
    Ignition coils
     
    Spark plug wires
     
    Upper intake manifold
     
    Oil filter
     
    Engine oil
     
    Transmission fluid level
     
    Negative battery cable
     

  16.  

The engine and transmission are removed and installed, as an assembly, from the vehicle.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Battery
     
    Fuel system pressure
     
    Coolant
     
    ECM located next to the battery
     
    Wiring harness from the starter and alternator
     
    Fuel supply and return lines from the fuel rail, then plug the openings to prevent contaminants from entering.
     
    Purge valve
     
    Intake hose/air flow meter assembly
     
    Throttle and cruise control cables from the throttle linkage
     
    All coolant hoses related to engine/transmission service
     
    Battery tray
     
    The 2 fuse box mounting bolts and pivot the fuse box aside.
     
    Engine wiring harness connector from the base of the fuse box
     
    Ground cable from the valance stud
     
    The 2 engine wiring harness connectors from the main harness
     
    Hood struts from the body locations. Raise the hood in the vertical position and stabilize.
     

  4.  
  5. Properly discharge the air conditioning system.
  6.  
  7. Remove or disconnect the following:

    Cooling fan and viscous coupling
     
    Grille
     
    Hood release cable strap from the upper radiator support
     
    Radiator upper support
     
    Left and right radiator air deflectors
     
    Washer bottle filler neck
     
    Engine and transmission oil coolers
     
    Coolant hoses from the radiator and thermostat housing
     
    The 2 fog lamp breather hoses from the clips on either side of the radiator
     
    Power steering fluid
     
    Transmission oil temperature sensor connector
     
    Refrigerant lines from the air conditioning condenser
     
    The 2 nuts and bolts securing the radiator mountings to chassis
     

  8.  
  9. With the aid of an assistant, raise the radiator assembly for access to the condenser cooling fan connectors.
  10.  
  11. Remove or disconnect the following:
    NOTE
    When attaching the engine lifting chain and hoist, it may be necessary to remove the oil filler cap to prevent it from being damaged. Place a cloth over plenum chamber to protect from damage during lifting.



    The 2 condenser cooling fan connectors
     
    Radiator/condenser/oil cooler assembly
     
    Window switch pack
     
    Parking brake and cable clevis pin
     
    Transmission fluid
     
    Transfer case fluid
     
    Engine oil
     
    Exhaust pipes from the manifolds
     
    Hand brake cable from the grommet in tunnel
     
    Rear driveshaft shaft guard
     
    Driveshafts
     
    Gear selector cable from the transmission lever
     
    The 2 bolts securing selector cable bracket to the transmission
     
    Transfer case fluid temperature sensor
     
    High/Low motor and output shaft speed sensor connectors
     
    Gear selection position switch and transmission speed sensor connectors
     
    Engine wiring harness-to-transmission harness connector
     
    The 4 nuts securing the engine mounts to the chassis and engine brackets
     

  12.  
  13. Install a suitable engine lifting chain and hoist.
  14.  
  15. Raise the engine slightly. Ensure that lifting bracket does not foul the bulkhead. Remove both engine mountings.
    NOTE
    It may be necessary to lower the transmission support slightly during the above operation.

  16.  
  17. Raise the engine/transmission and pull forward, while lowering the transmission support.
    NOTE
    The engine/transmission must be tilted at an angle of approximately 45 degrees before it can be removed from the engine compartment.

  18.  
  19. Remove the engine/transmission assembly.
  20.  

To install:

  1. Guide the engine into position.
  2.  
  3. With the aid of an assistant, raise the transmission and lower the engine until the engine mountings can be installed.
  4.  
  5. Attach the engine mounts to the chassis with new flange nuts, but do not tighten at this stage.
  6.  
  7. Lower and guide the engine onto the mounting studs.
  8.  
  9. Remove the engine lifting chain and hoist.
  10.  
  11. Route the transmission wiring harness.
  12.  
  13. The remaining step of the installation is the reverse of the removal procedure while keeping the following items in mind:

    Attach all wiring harness and electrical connectors.
     
    Align the driveshaft matchmarks and tighten the mounting nuts and bolts to 35 ft. lbs. (48 Nm).
     
    Attach all cables to the transmission.
     
    Tighten the engine mounting nuts to 33 ft. lbs. (45 Nm).
     
    Connect the parking brake cable and associated components.
     
    Install and connect the radiator/condenser/oil cooler assembly, using new sealing rings.
     
    Tighten the fittings on the air conditioning compressor to 17 ft. lbs. (23 Nm) and condenser to 11 ft. lbs. (15 Nm).
     
    Tighten the fittings for the power steering lines 12 ft. lbs. (16 Nm).
     
    Tighten the oil cooler lines to 22 ft. lbs. (30 Nm).
     

  14.  
  15. Evacuate and recharge the air conditioning system.
  16.  
  17. Connect the fuel supply and return lines to the fuel rail and tighten to 12 ft. lbs. (16 Nm).
  18.  
  19. Check and correct the fluid levels in the engine, transmission and transfer case.
  20.  
  21. Install and connect the battery.
  22.  
  23. Start the engine. Check for fuel, coolant and oil leaks.
  24.  

The engine and transmission are removed and installed, as an assembly, from the vehicle.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly discharge the air conditioning system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fuel system pressure
     
    Coolant
     
    Air intake plenum
     
    Mass airflow (MAF) sensor
     
    Cooling fan
     
    Battery positive lead on shock tower
     
    Ignition coil covers
     
    Camshaft cover ground wires
     
    Ignition coil connectors
     
    Throttle body, knock sensors, Camshaft Position (CMP) sensors, thermostat heater and coolant temperature sensor connectors
     
    Variable Camshaft Control (VCC) connectors
     
    Alternator connector
     
    Vacuum reservoir mounting bracket
     
    Fuel injector connectors
     
    Engine wiring harness from camshaft cover
     
    Air injection valve
     
    Charcoal canister connector
     
    Canister purge valve pipe and plug opening
     
    Transmission breather pipes from water pump
     
    Heater hoses
     
    Transmission connector bracket from bellhousing
     
    Starter connector
     
    Fuel feed line
     
    Necessary vacuum hoses
     
    Radiator hoses
     
    A/C connector
     
    A/C compressor and condenser lines and discard O-rings
     
    Oil pressure switch lines
     
    Oil filter housing and place aside
     
    Drain power steering fluid and remove hoses from power steering pump
     
    Remove power steering reservoir
     
    Sub-frame air deflector
     
    Exhaust pipes
     
    Front wheels
     
    Right halfshaft
     
    Front differential
     
    Lower engine ground
     
    Crankshaft Position (CKP) sensor
     
    Transmission cooler lines
     
    Torque converter bolts
     
    Starter
     

  6.  
  7. Place transmission jack under transmission.
  8.  
  9. Remove transmission-to-engine bolts
  10.  
  11. Install suitable engine lifting device to engine.
  12.  
  13. Remove engine mount attaching nuts.
  14.  
  15. Remove 2 top bellhousing bolts.
  16.  
  17. Raise engine clear of mounts and dowels and carefully remove the engine.
  18.  

To install:

  1. Install new o-ring to differential and lubricate with clean engine oil.
  2.  
  3. With the aid of an assistant, guide the engine into position onto the transmission, ensuring the torque converter is engaged properly.
  4.  
  5. Install the transmission-to-engine bolts and tighten to 33 ft. lbs. (45 Nm).
  6.  
  7. Install starter and tighten bolts to 33 ft. lbs. (45 Nm).
  8.  
  9. Install top 2 belhousing bolts and tighten to 18 ft. lbs. (25 Nm).
  10.  
  11. Remove transmission jack and lower engine onto mounts. Tighten mount nuts to 74 ft. lbs. (100 Nm).
  12.  
  13. Remove engine lifting device.
  14.  
  15. Install or connect the following:

    Drive plate bolts and tighten to 33 ft. lbs. (45 Nm).
     
    Exhaust pipes and tighten nuts to 33 ft. lbs. (45 Nm).
     
    Differential and tighten bolts to 81 ft. lbs. (110 Nm).
     
    Differential breathe hose
     
    Lower engine ground
     
    Sub-frame air deflector and tighten bolts to 33 ft. lbs. (45 Nm)
     
    Right halfshaft
     
    Power steering lines, using new 0-rings. Tighten nuts to 18 ft. lbs. (25 Nm).
     
    Oil filter housing
     
    Oil pressure switch connector
     
    A/C lines using new o-rings. Tighten fittings to 18 ft. lbs. (25 Nm).
     
    A/C connector
     
    Upper and lower radiator hoses
     
    Vacuum lines
     
    Fuel feed line
     
    Starter connector
     
    Transmission connector bracket
     
    Heater hoses
     
    Attach all wiring harness and electrical connectors
     
    Ignition coil covers
     
    Cooling fan
     
    Wheels and tighten to 103 ft. lbs. (140 Nm).
     
    Air intake plenum
     

  16.  
  17. Evacuate and recharge the air conditioning system.
  18.  
  19. Check and correct the fluid levels in the engine, power steering, transmission and transfer case.
  20.  
  21. Install and connect the battery.
  22.  
  23. Start the engine. Check for fuel, coolant and oil leaks.
  24.  

 
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