Engine Replacement

Engine Replacement

Tools Required

- J 42640 Steering Column Anti-Rotation Pin

Removal Procedure






1. Install the J 42640 to the steering column. Refer to Lower Intermediate Steering Shaft Replacement for the pin installation instructions Service and Repair.






2. Remove the shifter assembly mounting bolts (2). Refer to Shift Control Assembly Replacement Service and Repair.
3. Disconnect the positive and negative battery cables from the battery.
4. Remove the cross vehicle brace. Refer to Cross Vehicle Brace Replacement Service and Repair.
5. Remove the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement Service and Repair.
6. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement Service and Repair.
7. Disconnect the throttle body heater outlet hose from the throttle body and position the hose to the radiator.
8. Evacuate the air conditioning system. Refer to Refrigerant Recovery and Recharging Service and Repair.






9. Release the retainer (1) and disconnect the air conditioning suction hose from the evaporator. Refer to Suction Hose Replacement Service and Repair.
10. Remove the suction hose from the retaining feature (1) on the shock tower and position the hose to the engine.






11. Release the retainer (1) and disconnect the air conditioning liquid line from the connector at the front of dash. Disconnect the line from the connector at the radiator fan shroud. Remove the liquid line from the vehicle. Refer to Liquid Line Replacement Service and Repair.






12. Disconnect the brake booster vacuum hose from the brake booster. Position the hose to the engine.
13. Disconnect the brake fluid level switch electrical connector from the master cylinder.
14. Remove the master cylinder mounting nuts.
15. Remove the master cylinder brake lines from the retainers located on the left shock tower.
16. Position the master cylinder to the engine. Hold the master cylinder in place using mechanic's wire. Do not disconnect the brake lines from the master cylinder.






17. Disconnect the 2 electrical connectors, C105 and C107, at the left shock tower. Refer to Harness Routing Views Locations.
18. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Service and Repair.
19. Disconnect the chassis fuel line (3) from the engine fuel line (4) at the right rear of the engine. Refer to Metal Collar Quick Connect Fitting Service Service and Repair.
20. Disconnect the chassis-to-engine evaporative emission (EVAP) pipe (2) at the right rear of the engine. Refer to Evaporative Emission Hoses/Pipes Replacement - Engine Service and Repair.
21. Disconnect the engine wiring harness connector C102 at the front of dash. Refer to Harness Routing Views Locations.






22. Disconnect the underhood fuse block connector C103 (3) located between the right shock tower and the cam cover. Refer to Harness Routing Views Locations.
23. Remove the underhood electrical center cover.
24. Remove the negative battery cable bolt (1) from the fender flange near the hood shock.
25. Remove the negative battery cable from the retaining feature on the right shock tower and position the cable to the engine.
26. Remove the battery from the vehicle.






27. Remove the positive battery cable nut from inside the underhood electrical center. Remove the cable from the electrical center and position the cable to the engine.
28. Disconnect the chassis electrical connector at the top of the right shock tower. Position the wire to the engine.
29. Disconnect the engine wiring harness C5 connector from the inside of the underhood electrical center. Refer to Underhood Electrical Center or Junction Block Replacement Service and Repair.
30. Remove the ground strap bolt and strap from the right frame rail. Refer to Harness Routing Views Locations.
31. Drain the cooling system. Refer to Cooling System Draining and Filling Service and Repair.






32. Remove the electric cooling fan assembly. Refer to Engine Cooling Fan Replacement Service and Repair.
33. Remove the radiator assembly. Refer to Radiator Replacement Service and Repair.
34. Remove the air conditioner condenser assembly. Refer to Condenser Replacement Service and Repair.
35. Remove the power steering oil cooler mounting nuts (1) from the front frame assembly. Do not disconnect the lines from the cooler. Refer to Power Steering Fluid Cooler Replacement Service and Repair.
36. Position the power steering hose and the air conditioning suction hose to the engine and hold in place with mechanic's wire.
37. Remove the front tire and wheel assemblies.
38. Remove the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement .






39. Working through the right wheelhouse opening, remove the windshield washer reservoir-to-frame brace (2).






40. Remove the upper intermediate shaft to center intermediate shaft bolt.
41. Separate the upper intermediate shaft from the center intermediate shaft.
42. Lower the vehicle.






43. Disconnect the heater hoses from the engine.






44. Remove the 2 rear brake lines (1) from the brake pressure modulator valve (BPMV).
45. Pull the brake lines out from behind the wiring harness and secure the lines to the chassis with mechanic's wire.
46. Raise the vehicle.






47. Remove the transmission assembly. Refer to Transmission Replacement Service and Repair.
48. Remove the concentric slave cylinder. Refer to Clutch Concentric Actuator Cylinder Replacement Service and Repair.
49. Remove the brake bundle clips from the right and left frame rails. Remove the rear brake lines from the clip on the right frame rail.






50. Remove the engine control module (ECM) from the ECM housing. Refer to Engine Control Module Replacement Service and Repair.
51. Remove the (ECM) wiring harness screws (1).
52. Remove the ECM. Secure the ECM wiring harness to the engine.
53. Lower the vehicle.
54. Remove the right and left shock module upper mounting bolts.
55. Secure the shock modules to the front frame to avoid stretching the front brake hoses.
56. Raise the vehicle enough to place a suitable lift table under the engine, front frame, and front suspension assembly.

Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

57. Support the rear of the vehicle with suitable jackstands.
58. Raise the lift table, or lower the vehicle to preload the weight of the engine, front frame, and front suspension assembly.






59. Remove the front frame bolts.
60. With the aid of an assistant, lower the table and/or raise the vehicle to remove the engine, front frame, and suspension assembly from the vehicle.
61. Ensure that all the hoses, wires, pipes, and shock modules clear the vehicle during the removal process.
62. Install the J 41798 to the engine.
62. Using a suitable engine lift, remove the engine from the front frame assembly.

Installation Procedure






1. Install the engine to the front frame assembly.
2. Remove the J 41798 from the engine.
3. With the aid of an assistant, raise the table and/or raise the vehicle to install the engine, front frame, and suspension assembly to the vehicle.
4. Ensure that all the hoses, wires, pipes, and shock modules clear the vehicle during the installation process.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

5. Install the frame bolts.

Tighten
Tighten the frame bolts to 191 Nm (141 lb ft).

6. Install the right and left shock module upper mounting bolts.

Tighten
Tighten the shock module bolts to 112 Nm (83 lb ft).

7. Raise the vehicle and remove the lift table.






8. Connect the wiring harness (1) to the ECM and install the ECM to the vehicle. Refer to Engine Control Module Replacement Service and Repair.
9. Install the rear brake lines to the clip on the right frame rail. Install the brake bundle clips to the right and left frame rails.






10. Install the concentric slave cylinder. Refer to Clutch Concentric Actuator Cylinder Replacement Service and Repair.
11. Install the transmission assembly. Refer to Transmission Replacement Service and Repair.
12. Lower the vehicle.






13. Route the rear brake lines in front of the wiring harness. Install the 2 rear brake lines (1) to the BPMV. Refer to Brake Pressure Modulator Valve Replacement Service and Repair.






14. Connect the heater hoses to the engine.
15. Raise the vehicle.






16. Install the upper intermediate shaft to center intermediate shaft. Refer to Intermediate Steering Shaft Replacement - Center Service and Repair.






17. Install the windshield washer reservoir-to-frame brace (2). Refer to Windshield Washer Solvent Container Replacement Service and Repair.
18. Install the right wheelhouse liner. Refer to Front Wheelhouse Liner Replacement .
19. Install the front tire and wheel assemblies.
20. Install the power steering hose and air conditioning suction hose into the proper positions.






21. Install the power steering oil cooler and nuts (1) to the front frame. Refer to Power Steering Fluid Cooler Replacement Service and Repair.
22. Install the air conditioning condenser assembly. Refer to Condenser Replacement Service and Repair.
23. Install the radiator assembly. Refer to Radiator Replacement .
24. Install the electric cooling fan assembly. Refer to Engine Cooling Fan Replacement Service and Repair.
25. Install the ground strap to the right front frame rail. Refer to Harness Routing Views Locations.
26. Connect the engine wiring harness C5 connector at the inside of the underhood electrical center. Refer to Underhood Electrical Center or Junction Block Replacement Service and Repair.
27. Connect the chassis electrical connector located at the top of the right shock tower.






28. Install the positive battery cable and nut to the inside of the underhood electrical center.
29. Install the battery.
30. Install the negative battery cable to the retaining feature on the right shock tower.






31. Install the negative battery cable and bolt (1) to the right fender flange.
32. Install the underhood electrical center cover.
33. Connect the engine wiring harness connector C102 at the front of dash. Refer to Harness Routing Views Locations.






34. Connect the chassis-to-engine EVAP pipe (2) at the right rear of the engine. Refer to Evaporative Emission Hoses/Pipes Replacement - Engine Service and Repair.
35. Connect the chassis fuel line (3) to the engine fuel line (4) at the right rear of the engine. Refer to Metal Collar Quick Connect Fitting Service Service and Repair.
36. Connect the electrical connector C103 (3).
37. Connect the electrical connectors, C105 and C107, at the left shock tower. Refer to Harness Routing Views Locations.






38. Install the master cylinder. Refer to Master Cylinder Replacement Service and Repair.
39. Install the master cylinder brake lines to the retainers at the left shock tower.
40. Connect the brake fluid level switch electrical connector.
41. Connect the brake booster vacuum line to the brake booster.






42. Install the air conditioning liquid line and retainer (1) to the vehicle. Refer to Liquid Line Replacement Service and Repair.






43. Install the air conditioning suction hose and retainer (1) to the front of dash and the retaining feature on the left shock tower. Refer to Suction Hose Replacement Service and Repair.
44. Connect the throttle body heater outlet hose to the throttle body.
45. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement Service and Repair.
46. Install the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement Service and Repair.
47. Install the cross vehicle brace. Refer to Cross Vehicle Brace Replacement Service and Repair.
48. Connect the battery positive and negative cables to the battery.






49. Install the shifter assembly mounting bolts (2). Refer to Shift Control Assembly Replacement Service and Repair.






50. Remove the J 42640 from the steering column.
51. Fill the engine with engine oil. Refer to Fluid and Lubricant Recommendations and Approximate Fluid Capacities Specifications.
52. Check the transmission fluid level and add fluid as necessary. Refer to Transmission Fluid Level Inspection Service and Repair.
53. Fill the cooling system. Refer to Cooling System Draining and Filling Service and Repair.
54. Recharge the HVAC system. Refer to Refrigerant Recovery and Recharging Service and Repair.