Structural cover. Engine assembly

Structural cover

REMOVAL

(1) Raise vehicle on hoist.

(2) Remove the left hand exhaust pipe from exhaust manifold. Refer to Group 11, Exhaust System.

(3) Loosen the right hand exhaust manifold-to-exhaust pipe retaining bolts.

(4) Remove the eight bolts retaining structural cover (Fig. 39).

(5) Pivot the exhaust pipe downward and remove the structural cover.

INSTALLATION

CAUTION: The structural cover must be installed as described in the following steps. Failure to do so will cause severe damage to the cover.

(1) Position the structural cover in the vehicle.

(2) Install all four bolts retaining the cover-to-engine.

DO NOT tighten the bolts at this time.

(3) Install the four cover-to-transmission bolts. Do NOT tighten at this time.

CAUTION: The structural cover must be held tightly against both the engine and the transmission bell housing during tightening sequence. Failure to do so may cause damage to the cover.

(4) Starting with the two rear cover-to-engine bolts, tighten bolts (1) (Fig. 39) to 54 N*m (40 ft. lbs.), then tighten bolts (2) (Fig. 39) and (3) to 54 N*m ( 40 ft. lbs.) in the sequence shown.

Fig. 39 Structural Cover

(5) Install the exhaust pipe on left hand exhaust manifold.

(6) Tighten exhaust manifold-to-exhaust pipe retaining bolts to 20-26 N*m (15-20 ft. lbs.).

Engine assembly

REMOVAL

NOTE: This procedure applies to both the 4X2 and 4X4 vehicles, steps that apply to the 4X4 vehicle only, are identified.

(1) Disconnect the battery negative and positive cables.

(2) Remove the battery and the battery tray. Refer to BATTERY.

(3) Raise vehicle on hoist.

(4) Remove exhaust crossover pipe from exhaust manifolds. Refer to EXHAUST SYSTEM.

(5) 4X4 vehicles Disconnect axle vent tube from left side engine mount.

(6) Remove the through bolt retaining nut and bolt from both the left and right side engine mounts (Fig.

40) (Fig. 41).

(7) 4X4 vehicles Remove locknut from left and right side engine mount brackets (Fig. 41).

(8) Disconnect two ground straps from the lower left hand side and one ground strap from the lower right hand side of the engine.

(9) Disconnect crankshaft position sensor. (Fig. 43)

NOTE: The following step applies to 4X4 vehicles equipped with automatic transmission only.

(10) 4X4 vehicles Remove the axle isolator bracket from the engine, transmission and the axle (Fig. 42).

(11) Remove structural cover. Refer to Structural Cover in this section for procedure.

(12) Remove starter. Refer to STARTING SYSTEM.

(13) Drain cooling system. Refer to COOLING SYSTEM.

(14) Remove torque converter bolts (Automatic Transmission Only). Refer to TRANSMISSION.

(15) Remove transmission to engine mounting bolts.

(16) Disconnect the engine block heater power cable from the block heater, if equipped.

Fig. 40 Engine Mount Through Bolt and Nut Removal / Installation-4X2 Vehicles

1 - LOCKNUT AND WASHER

2 - ENGINE MOUNT/INSULATOR

3 - THROUGH BOLT

4 - FRAME

(17) Lower vehicle.

(18) Remove throttle body resonator assembly and air inlet hose.

(19) Disconnect throttle and speed control cables.

(20) Disconnect tube from both the left and right side crankcase breathers (Fig. 44). Remove breathers (21) Discharge A/C system. Refer to HEATING and AIR CONDITIONING.

(22) Remove A/C compressor.

(23) Remove shroud, fan assemblies and accessory drive belt. Refer to COOLING SYSTEM.

(24) Disconnect transmission oil cooler lines at the radiator.

(25) Disconnect radiator upper and lower hoses.

Refer to COOLING SYSTEM.

(26) Remove radiator, A/C condenser and transmission oil cooler as an assembly. Refer to COOLING SYSTEM.

(27) Remove generator.

(28) Disconnect the two heater hoses from the timing chain cover and heater core.

(29) Unclip and remove heater hoses and tubes from the intake manifold (Fig. 45).

(30) Disconnect engine harness at the following points :

• Intake air temperature (IAT) sensor (Fig. 46)
• Fuel Injectors

Fig. 41 Engine Mount Through Bolt and Nut Removal / Installation-4X4 Vehicles

1 - ENGINE MOUNT BRACKET (2)

2 - THROUGH BOLT (2)

3 - LOCKNUT AND WASHER (2)

4 - ENGINE ISOLATOR TO ENGINE MOUNT BRACKET STUD (2)

5 - LOCKNUT (2)

• Throttle Position (TPS) Switch
• Idle Air Control (IAC) Motor
• Engine Oil Pressure Switch
• Engine Coolant Temperature (ECT) Sensor
• Manifold absolute pressure (MAP) Sensor
• Camshaft Position (CMP) Sensor
• Coil Over Plugs

(31) Disconnect the vacuum lines at the throttle body and intake manifold.

(32) Release fuel rail pressure then disconnect the fuel supply quick connect fitting at the fuel rail.

Refer toFUEL SYSTEM for procedure.

(33) Remove power steering pump and position out of the way.

(34) Install Special Tools 8400 Lifting Studs, into the cylinder heads.

(35) Install Engine Lifting Fixture Special Tool 8347 (Fig. 47) following these steps.

• Holding the lifting fixture at a slight angle, slide the large bore in the front plate over the hex portion of the lifting stud.
• Position the two remaining fixture arms onto the two Special Tools 8400 Lifting Studs, in the cylinder heads.
• Pull foward and upward on the lifting fixture so that the lifting stud rest in the slotted area below the large bore.

Fig. 42 Axle Isolator Bracket Removal / Installation-4X4 Vehicles With Automatic Transmission

1 - TRANSMISSION

2 - AXLE ISOLATOR BRACKET

3 - FRONT AXLE 4X4 VEHICLES

4 - BOLTS

5 - ENGINE

• Secure the lifting fixture to the three studs using three 7/16 - 14 N/C locknuts.
• Make sure the lifting loop in the lifting fixture is in the last hole (closest to the throttle body) to minimize the angle of engine during removal.

(36) Disconnect body ground strap at the right side cowl (Fig. 48).

(37) Disconnect body ground strap at the left side cowl (Fig. 49).

NOTE: It will be necessary to support the transmission in order to remove the engine.

(38) Position a suitable jack under the transmission.

(39) Remove engine from the vehicle.

INSTALLATION

(1) Position engine in the vehicle.

Position both the left and right side engine mount brackets and install the through bolts and nuts.

Tighten nuts to 4X2 vehicles 95 N*m (70 ft. lbs.).

4X4 vehicles 102 N*m (75 ft. lbs.).

Fig. 43 Crankshaft Position Sensor

1 - CRANKSHAFT POSITION SENSOR

2 - CYLINDER HEAD COVER

3 - CAMSHAFT POSITION SENSOR

4 - RIGHT SIDE CYLINDER BLOCK

Fig. 44 Crankcase Breather Connection Points

1 - CRANKCASE BREATHERS

(2) 4X4 vehicles Install locknuts onto the engine mount brackets. Tighten locknuts to 41 N*m (30 ft.

lbs.).

(3) Remove jack from under the transmission.

(4) Remove Engine Lifting Fixture Special Tool 8347 (Fig. 47).

(5) Remove Special Tools 8400 Lifting Studs.

(6) Position generator wiring behind the oil dipstick tube, then install the oil dipstick tube upper mounting bolt.

(7) Connect both left and right side body ground straps.

Fig. 45 Heater Hoses and Tubes Removal / Installation

1 - HEATER HOSES AND TUBES

2 - ROUTING/RETAINING CLIPS

(8) Install power steering pump.

(9) Connect fuel supply line quick connect fitting.

(10) Connect the vacuum lines at the throttle body and intake manifold.

(11) Connect engine harness at the following points (Fig. 46) :

• Intake Air Temperature (IAT) Sensor
• Idle Air Control (IAC) Motor
• Fuel Injectors
• Throttle Position (TPS) Switch
• Engine Oil Pressure Switch
• Engine Coolant Temperature (ECT) Sensor
• Manifold Absolute Pressure (MAP) Sensor
• Camshaft Position (CMP) Sensor
• Coil Over Plugs

(12) Position and install heater hoses and tubes onto intake manifold.

(13) Install the heater hoses onto the heater core and the engine front cover.

(14) Install generator.

(15) Install A/C condenser, radiator and transmission oil cooler as an assembly.

(16) Connect radiator upper and lower hoses.

(17) Connect the transmission oil cooler lines to the radiator.

(18) Install accessory drive belt, fan assembly and shroud.

(19) Install A/C compressor. Tighten the A/C compressor and generator M10 mounting bolts 40-68N*M (30-50 ft. lbs.) and the M8 bolts 22-34 N*m (200-300 in. lbs.).

Fig. 46 Throttle Body Connection Points

1 - THROTTLE BODY

2 - TPS

3 - IAC MOTOR

4 - IAT SENSOR

5 - MOUNTING SCREWS

(20) Install both breathers. Connect tube to both crankcase breathers (Fig. 44).

(21) Connect throttle and speed control cables.

(22) Install throttle body resonator assembly and air inlet hose. Tighten clamps 4 N*m (35 in. lbs.).

(23) Raise vehicle.

(24) Install transmission to engine mounting bolts.

Tighten the bolts to 41 N*m (30 ft. lbs.).

(25) Install torque converter bolts (Automatic Transmission Only).

(26) Connect crankshaft position sensor (Fig. 43).

(27) 4X4 vehicles Position and install the axle isolator bracket onto the axle, transmission and engine block. Tighten bolts to specification. Refer to Specifications in this section.

(28) Install starter.

CAUTION: The structural cover requires a specific torque sequence. Failure to follow this sequence may cause severe damage to the cover.

Fig. 47 Engine Lifting Fixture Attachment Locations

1 - ATTACHING LOCATION

2 - ADJUSTABLE HOOK

3 - SPECIAL TOOL 8347 ENGINE LIFT FIXTURE

4 - ATTACHING LOCATIONS

(29) Install structural cover. Refer to Structural Cover in this section.

(30) Install exhaust crossover pipe.

(31) Install engine block heater power cable, If equipped.

(32) 4X4 vehicles Connect axle vent tube to left side engine mount.

(33) Lower vehicle.

(34) Check and fill engine oil.

(35) Recharge the A/C system.

(36) Refill the engine cooling system. Refer to COOLING SYSTEM.

(37) Install the battery tray and battery.

(38) Connect the battery positive and negative cables.

(39) Start the engine and check for leaks.

Fig. 48 Body Ground Strap-Right Side Removal / Installation

1 - NUT

2 - A/C ACCUMULATOR

3 - GROUND STRAP