Engine Replacement

Engine Replacement

Tools Required
* J 28467-86 Engine Lift Bracket
* J 28467-87 Engine Lift Bracket
* J 42640 Steering Column Anti-Rotation Pin

Removal Procedure

1. Install J 42640 to the steering column.




2. Remove the engine compartment sight shields.
3. Disconnect the positive and negative battery cables from the battery.
4. Remove the cross vehicle brace.
5. Remove the fuel injector sight shield.




6. Remove the air cleaner assembly.
7. Remove the supercharger inlet duct assemblies.
8. Drain the cooling system.
9. Drain the charge air cooling system.
10. Disconnect the surge tank inlet hose from the fittings on the water outlet housing.
11. Disconnect the inlet hose from the radiator and position the hose to the vehicle.




12. Evacuate the air conditioning system.
13. Remove the air conditioning liquid line from the vehicle.
14. Disconnect the air conditioning suction hose from the evaporator core.
15. Remove the suction hose from the retaining feature (1) on the left shock tower and position the hose to the engine.




16. Disconnect the brake fluid level switch electrical connector on the master cylinder.
17. Remove the master cylinder mounting nuts.
18. Position the master cylinder to the engine. Hold the master cylinder in place with mechanics wire. Do not disconnect the brake lines from the master cylinder.




19. Relieve the fuel system pressure.
20. Disconnect the fuel line (4) from the fuel rail and position the line to the vehicle.
21. Disconnect the charge air cooler reservoir hose from the reservoir. Position the hose and the charge air cooler fill port to the engine.
22. Disconnect the engine wiring harness connector C102 at the front of dash.
23. Disconnect the underhood fuse block connector C5 located between the right shock tower and the cam cover.
24. Remove the underhood electrical center cover.




25. Disconnect the battery current sensor electrical connector.
26. Remove the negative battery cable bolt from the right shock tower. Remove the cable retainer from the stud on the right shock tower and position the cable to the engine.
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 both of the chassis electrical connectors at the top of the right shock tower. Position the wires to the engine.
29. Disconnect the engine wire harness C5 connector from inside of the underhood electrical center.
30. Remove the engine cooling fans.




31. Raise and support the vehicle. Refer to Vehicle Lifting.
32. Remove the front tire and wheel assemblies.
33. Remove the right and left wheelhouse splash shields.
34. Remove the right and left wheelhouse liners.




35. Working through the right wheelhouse opening, remove the windshield washer reservoir brace from the frame and disconnect the chassis wire harness electrical connector.
36. Working through the left wheelhouse opening, disconnect the transmission oil cooler lines located near the air conditioning compressor.
37. Remove the bolt (3) that secures the center intermediate shaft to the lower intermediate shaft.
38. Separate the 2 shafts.
39. Remove the bolts securing the power steering cooler lines to the radiator assembly.
40. Remove the supercharger charge air cooler radiator.
41. Remove the radiator, condenser, and transmission oil cooler as an assembly.
42. Raise and support the vehicle. Refer to Vehicle Lifting.
43. Remove the bolts from the mounting bracket on the power steering oil cooler. Position the oil cooler to the engine. Secure the cooler to the engine with mechanics wire.
44. Disconnect the top heater hose from the water outlet housing and position the hose to the vehicle.




45. Remove the transmission assembly.
46. Remove the brake bundle clips from the front frame rails. Do not remove the lines from the clips.
47. Disconnect the fuel feed line from the fuel filter.
48. Disconnect the evaporative emission (EVAP) hose connection from the rear of the fuel filter.
49. Disconnect the rear brake lines from the bracket above the rear axle assembly on the right side of the vehicle.
50. Remove the fuel and brake line bundle retainers from the frame rail along the length of the vehicle. Do not remove the retainers from the lines.
51. Remove the fuel and brake line bundle bracket from the right side wheelhouse.
52. Lower the vehicle.




53. Disconnect the outlet hose from the heater outlet pipe at the right frame rail. Position the hose to the engine.
54. Disconnect the inlet hose from the water housing and position the hose to the vehicle.
55. If the vehicle is equipped with Magnaride, disconnect the electrical connectors from the top of the right and left shock modules.
56. Remove the upper mounting bolts from the right and left shock module.
57. Secure the shock modules to the front frame with mechanics wire to avoid stretching the front brake hoses.




58. 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.

59. Support the rear of the vehicle with suitable jack stands.
60. Raise the lift table and/or lower the vehicle to preload the weight of the engine, front frame, and front suspension assembly.
61. Remove the front frame bolts (2).
62. With the aid of an assistant, lower the table and/or raise the vehicle to remove the engine, front frame, fuel/brake bundle, and front suspension assembly from the vehicle.
63. Ensure that all the hoses, wires, pipes, and shock modules clear the vehicle during the removal process.




64. Install J 28467-86 to the left cylinder head.




65. Install J 28467-87 to the right cylinder head.
66. Using a suitable engine lift, remove the engine from the front frame assembly.

Installation Procedure




1. Install the engine to the front frame.
2. Ensure that all the hoses, wires, pipes, and shock modules are positioned out of the way to avoid contact during engine installation.
3. With the aid of an assistant, raise the table and/or lower the vehicle to install the engine, front frame, fuel/brake bundle, and front suspension.

Notice: Refer to Fastener Notice.

4. Install the frame bolts.

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




5. Install the right and left upper shock modules bolts.

Tighten the bolts to 112 N.m (83 lb ft).

6. If the vehicle is equipped with Magnaride, connect the shock module electrical connectors.
7. Connect the heater inlet hose to the water housing.
8. Connect the heater outlet hose to the outlet pipe.
9. Raise the vehicle. Refer to Vehicle Lifting.
10. Install the fuel and brake line bundle bracket to the right side wheelhouse.

Tighten the bracket bolt to 9 N.m (80 lb in).

11. Install the fuel and brake line to the bundle brackets, the length of the vehicle.
12. Install the rear brake line to the bracket bolt above the rear axle assembly.
13. Connect the EVAP hose to the rear of the fuel filter.
14. Connect the fuel feed line to the fuel filter.
15. Install the brake lines to the bundle clips on the right and left frame rails.




16. Install the transmission assembly.
17. Connect the top heater hose to the water outlet housing.
18. Install the powers steering oil cooler and mounting bracket.
19. Lower the vehicle.
20. Install the radiator, condenser, and transmission oil cooler as an assembly.
21. Install the supercharger charge air cooler radiator assembly.
22. Install the bolt that secures the power steering lines to the radiator.

Tighten the bolt to 9 N.m (80 lb in).




23. Connect the center intermediate shaft to the lower intermediate shaft.
24. Install the bolt (3) that secures 2 shafts.

Tighten the bolt to 30 N.m (23 lb ft).

25. Working through the left wheelhouse, connect the transmission oil cooler lines near the air conditioning compressor.
26. Working through the right hand wheelhouse, connect the wire harness connector and install the bolt that secures the washer fluid reservoir to the front frame brace.

Tighten the bolt to 6 N.m (53 lb in).




27. Install the right and left front wheelhouse liners.
28. Install the right and left wheelhouse splash shields.
29. Install the right and left front tire assemblies.
30. Lower the vehicle.
31. Install the cooling fan.
32. Connect the engine wire harness C5 connector to the inside of the underhood electrical center.
33. Connect both of the chassis electrical connectors at the top of the left shock tower.
34. Install the positive battery cable to the underhood bussed electrical center.

Tighten the battery cable nut to 15 N.m (11 lb ft).




35. Install the negative battery cable retainer and bolt to the right hand shock tower.

Tighten the retainer bolt to 36 N.m (27 lb ft).

36. Connect the battery current sensor electrical connector (1).
37. Install the underhood electrical center cover.
38. Connect the underhood fuse block connector C5.
39. Connect the front of the dash electrical connector C102.
40. Connect the charge air cooler reservoir hose to the reservoir.




41. Connect the chassis fuel line (4) to the fuel rail.
42. Install the brake master cylinder.

Tighten the retaining nuts to 25 N.m (18 lb ft).

43. Connect the brake fluid level switch.




44. Install the air conditioning liquid and suction lines.
45. Connect the coolant surge tank hose to the radiator.
46. Connect the coolant surge tank hose to the fittings on the water outlet housing.
47. Install the supercharger inlet duct assemblies.




48. Install the air cleaner assembly.
49. Install the fuel injector sight shield.
50. Install the cross vehicle brace.




51. Install the front engine compartment sight shields.
52. Install the positive battery cable.
53. Install the negative battery cable.
54. Remove the J 42640 steering wheel anti-rotation pin.
55. Fill the engine with engine oil.
56. Fill the cooling system.
57. Fill the charge air cooling system.
58. Recharge the air conditioning system.
59. Bleed the brake system.