Diesel Data: Automotive Repair

Removal and Replacement

ENGINE - 3.2L

REMOVAL
1. Disconnect the negative battery cable.
2. Drain the cooling system
3. Remove the air cleaner housing assembly.





4. Relieve the fuel pressure at the service valve (1) on the fuel rail.
5. Remove the radiator fan assembly.
6. Remove the accessory drive belt.
7. Disconnect the vacuum hoses at the brake booster, intake manifold, and the purge valve.





8. Remove the oil from the power steering pump reservoir.
9. Disconnect the ground lead at the power steering pump.
10. Disconnect the pressure (2) and return (1) lines from the power steering pump.





11. Disconnect the oxygen sensor harness connectors (1), MAF sensor harness connector (2), heater hose (3) at rear of engine, and the fuel supply line (4) at the fuel rail.
12. Disconnect the ignition coil(s), fuel injector(s), camshaft position sensor, crankshaft position sensor, throttle position sensor, map sensor, engine coolant temperature sensor, EGR solenoid, air pump, air pump switchover solenoid, A/C compressor, and generator harness connectors. Reposition the engine harness out of the way.





13. Remove the lower radiator hose (1) and the coolant bypass hose (2) from the water pump.





14. Remove the upper radiator hose (1) from the thermostat housing.





15. Raise and support the vehicle.
16. Remove the lower splash shield retaining screws (1) and the splash shield (2).
17. Remove the front exhaust pipes.





18. Disconnect the ground cable (1) at the transmission.
19. Remove the propeller shaft.
20. Remove the starter motor.
21. Remove the transmission.
22. Remove the A/C compressor mounting bolts and position the A/C compressor out of the way with lines attached.





23. Remove the front engine mount bolts (1).
24. Lower the vehicle.
25. Attach the engine lifting device to the engine lifting eyes.
26. Remove the engine assembly from the vehicle.
27. Mount the engine on an engine stand.

INSTALLATION





1. Attach the lifting device to the engine lifting eyes.
2. Remove the engine from the engine stand.
3. Lower the engine into the engine compartment and install the lower engine mount bolts (1). Tighten bolts to 55 Nm (41 ft. lbs.).
4. Install the transmission.
5. Install the A/C compressor.





6. Bolt on the ground cable at the transmission (1). Tighten to 40 Nm (30 ft. lbs.).
7. Install the starter.
8. Install the propeller shaft.
9. Install the front exhaust pipes.





10. Install the lower splash shield (2). Tighten the screws (1) to 5 Nm (44 in. lbs.).
11. Lower the vehicle.





12. Connect the lower radiator hose (1) and the coolant bypass hose (2) at the water pump.
13. Connect the heater hoses at the engine block and the intake manifold.





14. Connect the upper radiator hose (1) at the thermostat housing.
15. Connect the engine wire harness.





16. Connect the fuel supply line (4) at the fuel rail. Tighten the fitting to 38 Nm (28 ft. lbs.).
17. Connect the oxygen sensor harness connector (1), MAF sensor harness connector (2), and the heater hose (3) at rear of engine.
18. Connect the ignition coil(s), fuel injector(s), camshaft position sensor, crankshaft position sensor, throttle position sensor, map sensor, engine coolant temperature sensor, EGR solenoid, air pump, air pump switchover solenoid, A/C compressor, and generator harness connectors.





19. Connect the power steering pressure (2) and return line (1) to the power steering pump. Tighten the high pressure fitting to 45 Nm (33 ft. lbs.).
20. Connect the ground lead at the power steering pump. Tighten the bolt to 25 Nm (18 ft. lbs.).
21. Refill the power steering pump fluid reservoir.
22. Connect the vacuum hoses at the brake booster, intake manifold, and the purge valve.
23. Install the accessory drive belt.
24. Install and connect the radiator with the radiator fan
25. Install the air cleaner assembly.
26. Connect the negative battery cable.
27. Fill the cooling system
28. Fill the engine with engine oil.
29. Start the engine and check for leaks.
30. Recheck all fluid levels.