Removal

Engine Replacement (5L40-E)
The following procedure requires the removal of the engine and transmission as an assembly.

Tools Required
^ J38185 Hose Clamp Pliers
^ J39456 Universal Engine Tilter
^ J42098 Crank Hub TORX� Socket

Removal Procedure
1. Remove the hood.
2. Remove the wiper motor module.
3. Remove the fasteners securing the front air inlet panel to the battery tray and cowl.
4. Remove the front air inlet panel from the vehicle.
5. Disconnect the battery negative cable.





6. Remove the bolt (1) securing the battery negative cable to the side rail.
7. Disconnect the body harness connector (3) from the battery negative cable and secure to the engine.





8. Depress the tabs in order to remove the underhood fuse block cover from the underhood fuse block.





9. Remove the nut (1) securing the battery positive cable (2) to the underhood fuse block.
10. Disconnect the battery positive cable from the battery and secure to the engine.
11. Disconnect the engine wiring harness electrical connector from the underhood fuse block and secure to the engine.
12. Disconnect the engine wiring harness connector at the right shock tower and secure to the engine.





13. Unlock the transmission control module electrical connector by pulling the retainer (2) away from the electrical connector (1).

Important: Twisting or tilting of the transmission control module electrical connector while disconnecting may result in bent or misaligned electrical terminal pins.

14. Carefully disconnect the electrical connector (1) from the transmission control module and secure to the engine.
15. Remove the air cleaner assembly.
16. Remove the intake air resonator.





17. Disconnect the engine wiring harness connector (1) from the coolant bypass solenoid.





18. Remove the bolt securing the engine wiring harness ground lead to the right body rail.
19. Drain the cooling system.





20. Position the J38185 to the clamps in order to remove the surge tank inlet hose from the following:
^ The radiator
^ The throttle body assembly

21. Remove the inlet radiator hose.
22. Remove the outlet radiator hose.





23. Position the J38185 to the clamp (2) in order to remove the coolant bypass outlet hose from the coolant inlet pipe.





24. Position the J38185 to the clamp (1) in order to remove the coolant bypass inlet hose from the afterboil coolant pump pipe.
25. Relieve the fuel system pressure.





26. Refer to Quick Connect Fitting(s) Service (Metal Collar).
^ The return hose/pipe (1)
^ The feed hose/pipe (2)Plug the open outlet ports to prevent fuel loss and contamination.

27. Disconnect the Evaporative Emission (EVAP) quick connect fitting (3).
28. Open the retainer (4) located at the engine control module (ECM) bracket in order to remove the chassis hose/pipes.





29. Position the J38185 to the clamp (1) in order to remove the outlet heater hose from the afterboil coolant pump (2).





30. Position the J38185 to the clamp (1) in order to remove the inlet heater hose from the heater core.
31. Position the J38185 to the clamp in order to remove the surge tank outlet hose from the surge tank and secure to the engine.





32. Disconnect the electrical connector (1) from the Air Conditioning (A/C) refrigerant pressure sensor (2).
33. Disconnect the 2 engine wiring harness connectors from the left body rail connectors.





34. Remove the power steering return hose nut and retainer from the A/C compressor stud.





35. Disconnect the retainer (1) securing the engine wiring harness to the A/C pressure hose and secure to the engine.





36. Remove the power steering pressure hose nut and retainer from the A/C compressor stud.
37. Remove the drive belt.





38. Remove the power steering pump mounting bolts ONLY.
39. Remove the power steering pump from the accessory mounting bracket, and position aside.





40. Disconnect the following from the remote power steering fluid reservoir (1):
^ The vacuum brake booster hose
^ The wiring harness (2)

41. Disconnect the vacuum brake booster hose from the vacuum source.





42. Remove the remote power steering fluid reservoir mounting bolts (1,3) ONLY, and position aside.





43. Disconnect the electrical connector from the A/C compressor.

Important: Evacuation of the A/C refrigerant will not be necessary.

44. Remove the A/C compressor mounting bolts ONLY, and position aside.
45. Raise and support the vehicle.
46. Remove the exhaust system.
47. Remove the left and right catalytic converters. and Catalytic Converter Replacement - Right (LA3, LY9) Catalytic Converter Replacement - Right (LY7) Catalytic Converter Replacement - Right (LS6) in Engine Exhaust.
48. Remove the catalytic converter hanger bracket.





49. Remove the Electronic Brake Control Module (EBCM) connector position assurance retainer (4) from the EBCM electrical connector (1).
50. Rotate the EBCM connector tab (2) up into the unlocked position.
51. Disconnect the EBCM electrical connector (1) from the EBCM (3).
52. If equipped, disconnect the electrical connector from the brake fluid pressure sensor.





53. Disconnect the Antilock Brake System (ABS) wiring harness electrical connectors from the left and right wheel speed sensors.






Important: Note the routing of the ABS wiring harness.

54. Remove the ABS wiring harness retainers from the following:
^ The lower control arms
^ The electric cooling fan





55. Remove the ABS wiring harness retainers (2) from the engine frame.
56. If equipped, disconnect the variable effort steering electrical connector (1) from the power steering gear pigtail.
57. Remove the transmission fluid cooler pipes.
59. Remove the oil filter adapter.





60. Remove the right engine mount upper retaining nut.





61. Remove the left engine mount upper retaining nut.





62. Remove the transmission manual shift shaft nut.
63. Disconnect the shift linkage from the transmission.
64. Place the transmission in neutral by rotating the transmission shift shaft clockwise.





65. Disconnect the propeller shaft coupler (1) from the transmission flange ONLY.





66. Secure the front propeller shaft (1) to the shift control lever (3) with a piece of mechanics wire (2).





67. Remove the transmission mount nuts.





68. Remove the inner transmission support mounting bolts.
69. Lower the vehicle.
70. Using a lift jack support the rear of the transmission.





71. Remove the outer transmission support mounting bolts.





72. Remove the transmission support from the vehicle.





73. Install the J39456 to the engine lift brackets and attach to an engine lift devise.

Important: Ensure clearance is maintained between the engine/transmission assembly and the following:
^ The A/C compressor
^ The A/C hoses
^ The brake pipes at the BPMV
^ The coolant bypass valve
^ The electric cooling fans
^ The engine wiring electrical harness
^ The fuel hoses
^ The power steering pump
^ The radiator
^ The remote power steering fluid reservoir
^ The vehicles tunnel

74. Alternate between the following in order to remove the engine/transmission assembly from the engine compartment:
^ Carefully raise the engine/transmission assembly using the engine lift devise.
^ Lower the lift jack supporting the rear of the transmission enough to clear the vehicles tunnel.

75. Lower the engine/transmission assembly to the floor.

Important: The following are on-vehicle procedures, use only the portion of the procedure needed for removal of the component.

76. Remove the following components from the engine if necessary:
^ Afterboil Coolant Pump Replacement in Engine Cooling
^ Battery Negative Cable Replacement (LHD) Battery Negative Cable Replacement (RHD) Battery Negative Cable Replacement (LY7) Battery Negative Cable Replacement (LS6) in Engine Electrical
^ Battery Positive Cable Replacement (LHD) Battery Positive Cable Replacement (RHD) Battery Positive Cable Replacement (LY7) Battery Positive Cable Replacement (LS6) in Engine Electrical
^ Coolant Heater Cord Replacement (LA3, LY9, K05) Coolant Heater Cord Replacement (LA3, LY9, KA3) Coolant Heater Cord Replacement (LY7 (KO5)) Coolant Heater Cord Replacement (LS6) in Engine Cooling
^ Coolant Pipe Replacement - Inlet (LA3, LY9) Coolant Pipe Replacement - Inlet (LY7) in Engine Cooling
^ Generator Replacement (LA3, LY9) Generator Replacement (LS6) Generator Replacement (LY7) in Engine Electrical
^ Starter Motor Replacement (LA3, LY9) Starter Motor Replacement (LY7) Starter Motor Replacement (LS6) in Engine Electrical
^ Surge Tank Hose/Pipe Replacement - Outlet (LHD, LY7) Surge Tank Hose/Pipe Replacement - Outlet (LHD) Surge Tank Hose/Pipe Replacement - Outlet (RHD) Surge Tank Hose/Pipe Replacement - Outlet (LS6) in Engine Cooling
^ Throttle Body Heater Hose/Pipe Replacement - Inlet (LA3, LY9) Throttle Body Heater Hose/Pipe Replacement - Inlet (LS6) in Engine Cooling





77. Remove the 2 bolts (2-4) securing the engine wiring harness ground leads (1-3) to the left cylinder head.





78. Remove the right engine mount retaining bolts and bracket.





79. Remove the left engine mount retaining bolts and bracket.
80. Disconnect the engine wiring harness retainers.
81. Disconnect the engine wiring harness connectors from the electrical components.





82. Disconnect the engine wiring harness retaining clips (1) from the transmission mounting bolts.

Important: Note the routing of the engine wiring harness.

83. Remove the engine wiring harness from the engine.





84. Remove the transmission close out plug.
85. Mark the torque converter to flexplate/flywheel orientation to ensure proper realignment.





86. Remove the torque converter bolt close out plug from the engine block by pulling outward.






Important: NEW torque converter bolts will be required each time the torque converter bolts are removed.

87. Repeat the following steps for all 3 torque converter bolts:
1. Rotate the crankshaft center bolt in the engine rotational direction, clockwise using the J42098, in order to align the torque converter bolts with the access hole in the engine block.
2. Remove and discard the torque converter bolt. The bolt is self locking and is NOT reusable.





88. Remove the 3 lower transmission mounting bolts (1-2).





89. Remove the 3 upper transmission mounting bolts (2-3).
90. Pull the transmission free from the engine dowels (1).
91. With the aid of an assistant remove the transmission from the engine.
92. Remove the J39456 from the engine.