Removal Procedure
Engine Replacement
^ Tools Required
- EN 46114 Engine Lift Brackets
- J 42640 Steering Column Anti-Rotation Pin
Removal Procedure
1. Center the steering wheel.
2. Turn the ignition OFF.
3. Install J 42640 to the steering column.
4. Important: Do NOT disconnect the battery cables from the engine.
Disconnect the negative cable from the battery and the body.
5. Disconnect the positive cable from the battery and the underhood electrical center.
6. Position and secure the battery cables to the engine.
7. Remove the battery.
8. Remove the fuel injector sight shield.
9. Remove the air cleaner duct.
10. Disconnect the cooling fan electrical connectors (2, 3).
11. Remove the cooling fan wiring harnesses (1, 4) from the fan shroud.
12. Secure the wiring harnesses to the vehicle.
13. Drain the cooling system. Refer to Draining and Filling Cooling System (Static Fill) Draining and Filling Cooling System (GE 47719).
14. Important: Do NOT disconnect the surge hoses from the engine or the radiator.
Disconnect the surge tank outlet hose from the surge tank.
15. Position and secure the surge hose to the engine.
16. Disconnect the surge tank inlet hose from the water outlet housing and the radiator.
17. Position and secure the surge tank inlet hose to the vehicle.
18. Disconnect the heater hoses from the heater core.
19. Disconnect the purge line (3) from the purge solenoid.
20. Disconnect the fuel pipe (2) from the fuel rail.
21. Plug the fuel pipe and cap the fuel rail to prevent fuel loss or contamination.
22. Evacuate the air conditioning system. Refer to Refrigerant Recovery and Recharging.
23. Remove the wiper module.
24. Important: Do NOT disconnect the suction hose from the A/C compressor.
Disconnect the air conditioning suction hose from the evaporator and remove the suction hose bracket from the shock tower.
25. Position and secure the suction hose to the engine.
26. Important: Do NOT disconnect the liquid line from the condenser.
Disconnect the air conditioning pressure switch electrical connector and remove the liquid line .
27. Remove the radiator support brackets.
28. Disconnect the brake booster check valve and vacuum hose (1) from the brake booster (2).
29. Position and secure the brake booster hose to the engine.
30. Disconnect the electrical connector to the brake fluid level switch from the master cylinder.
31. Disconnect the electrical connector to the mass air flow sensor.
32. Unlock and disconnect the instrument panel (I/P) electrical connector from the engine located at the rear of the left bank 2 cylinder head.
33. Position and secure the I/P harness to the vehicle.
34. Disconnect the engine module wiring harness connectors (1-3) from the underhood electrical center.
35. Disconnect the wiring harness from the transmission control module (TCM).
36. Remove the ground bolt and wire from the longitudinal rail.
37. Disconnect the engine harness electrical connector at the longitudinal rail.
38. Position and secure the ground wire, the engine harness and the TCM harness to the engine.
39. Important: Do NOT disconnect the brake pipes from the master cylinder.
Remove the master cylinder nuts.
40. Reposition and secure the master cylinder to the engine.
41. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
42. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
43. Remove the muffler assembly.
44. Remove the propeller shaft.
45. Remove the air deflector.
46. Important: DO NOT remove the water bottle.
Remove the washer bottle bracket.
47. Disconnect the side air baffles from the radiator.
48. Disconnect the left front brake pipe retainer along with the brake pipe from the longitudinal rail.
49. Remove the right front brake pipe from the brake pipe bundle retainer.
50. Disconnect the rear brake pipes from the brake pressure modulator valve (BPMV).
51. Plug the brake pipes and the brake modulator valve in order to minimize brake fluid loss.
52. Remove the front tire and wheel assemblies.
53. Remove the lower intermediate steering shaft.
54. Remove the lower engine mount nuts.
55. Disconnect the transmission shift linkage from the transmission.
56. Disconnect the electrical connector to the low oil level sensor. Secure the electrical connector and the harness to the engine mount bracket.
57. Remove the headlamp leveling sensors.
58. Secure the shock modules to the lower control arms with a suitable strap in order to prevent damage to the front brake hoses.
59. Remove the upper mounting bolts from the right and left shock module.
60. Raise the vehicle enough to place a suitable lift table under the engine, transmission, front frame and front suspension assembly.
61. Position a suitable powertrain or engine lift table below the frame, engine and transmission.
62. Raise the lift table or lower the vehicle to support the frame, engine and transmission.
63. Remove the bolts which secure the transmission brace to the underbody.
64. Remove the front frame bolts (2).
65. Important: Ensure that all the hoses, wires, pipes and shock modules clear the vehicle during the removal process.
With the aid of an assistant, lower the table or raise the vehicle to remove the engine, transmission, front frame and front suspension assembly from the vehicle.
66. Disconnect the engine control module (ECM) upper electrical connector.
67. Important: Do NOT remove the oxygen sensors.
Remove the catalytic converters with the oxygen sensors.
68. Remove the thermostat housing with the heater pipes, heater hoses and surge tank outlet hose.
69. Remove the starter motor.
70. Remove the flywheel bolts.
71. Remove the heated oxygen sensor (HO2S) connector bracket (1) from the left cylinder head.
72. Remove the engine wiring harness and related components.
73. Disconnect the transmission oil cooler pipes from the engine, radiator and the transmission.
74. Disconnect the radiator hoses from the water outlet housing and the coolant inlet pipe.
75. Disconnect the power steering cooler hoses from the condenser radiator and fan module (CRFM).
76. Plug the power steering hoses and pipes in order to prevent fluid loss and contamination.
77. Remove the CRFM with the radiator hoses from the frame.
78. Install EN 46114 to the engine.
79. Connect a floor crane to the engine lift brackets and raise the floor crane to partially support the engine.
80. Position a second powertrain lift table below the transmission.
81. Remove the bolts that secure the transmission to the engine.
82. Remove the transmission from the engine.
83. Remove the drive belts.
84. Remove the generator and water pump drive belt tensioner.
85. Remove the A/C compressor and power steering drive belt tensioner.
86. Remove the generator and the generator bracket.
87. Remove the A/C compressor.
88. Remove the power steering pump.
89. Remove the power steering reservoir from the engine.
90. Remove the oil level indicator.
91. Remove the left exhaust manifold.
92. Remove the oil filter adapter.
93. Remove the right exhaust manifold.
94. Remove the crankshaft balancer.
95. Remove the flywheel.
96. Remove the intake manifold.
97. Remove the water outlet.
98. Remove the block heater.
99. Remove the ECM with the ECM bracket.
100. Use a floor crane in order to remove the engine from the frame.
101. Remove the engine mount brackets with the engine mounts.