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. Disconnect the positive and negative battery cables from the battery.
3. Remove the cross vehicle brace.
4. Remove the fuel injector sight shield.




5. Remove the air cleaner assembly.
6. Disconnect the surge tank inlet hose and position the hose to the engine.




7. Evacuate the air conditioning system.
8. Disconnect the air conditioning suction hose fitting at the top of the left shock tower.
9. Remove the suction hose from the retaining feature (1). Position the line to the engine.
10. Disconnect the air conditioning liquid line from the condenser.
11. Remove the air conditioning liquid line from the retaining feature on the fan shroud.




12. Disconnect the brake booster vacuum line (1) from the brake booster (2). Position the brake booster line to the engine.
13. Disconnect the electrical connector on the brake fluid level switch from the master cylinder.




14. Remove the master cylinder mounting nuts.
15. Position the master cylinder to the engine. Hold the master cylinder in position by using mechanics wire. Do not disconnect the brake lines from the master cylinder.
16. Relieve the fuel system pressure.




17. Remove the fuel line retainer (1) from the vehicle. The retainer is located on the bracket attached to the heater lines on the front of the dash.
18. Disconnect the engine wiring harness connector C102 at the front of the dash.
19. Disconnect the underhood fuse block connector C5 located between the right shock tower and the cam cover.
20. Remove the underhood electrical center cover.




21. Remove the negative battery cable (2) 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.




22. 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.
23. Disconnect the chassis electrical connector at the top of the right shock tower. Position the wire to the engine.
24. Disconnect the electrical connector for the transmission control module and position the wiring harness to the engine.
25. Disconnect the engine wiring harness C5 connector from the inside of the underhood electrical center.
26. Disconnect the electrical connector C113 at the right frame rail.
27. Remove the engine cooling fans.

* Fan Replacement (LH2) Fan Replacement (LY7)
* Engine Cooling Fan Replacement (LH2 Heavy Duty Cooling) Engine Cooling Fan Replacement (LH2 Standard Cooling) Engine Cooling Fan Replacement (LY7)

28. Raise and support the vehicle. Refer to Vehicle Lifting.
29. Remove the front tire and wheel assemblies.




30. Remove the right and left wheelhouse splash shields.
31. Remove the right and left wheelhouse liners.
32. Working through the right wheelhouse, remove the brace that secures the windshield washer reservoir to front frame.
33. Place a suitable drain pan under the vehicle.
34. Working through the left wheelhouse, disconnect the transmission oil cooler lines located near the air conditioning compressor.




35. Remove the bolt (3) that secures the center intermediate shaft to the lower intermediate shaft.
36. Separate the 2 shafts.
37. Drain the cooling system.




38. Remove the bolt securing the power steering cooler lines to the radiator assembly.
39. Lower the vehicle.
40. Remove the radiator, condenser, and transmission oil cooler as an assembly.
41. Raise the vehicle.
42. 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.




43. Remove the transfer case, if equipped.
44. Remove the transmission assembly.
45. Remove the brake bundle clips from the right and left frame rails. Do not remove the clips from the brake lines.
46. Disconnect the fuel line from the fuel filter.
47. Disconnect the evaporative emission (EVAP) hose connection at the rear of the fuel filter.
48. Disconnect the rear brake lines from the bracket above the rear axle assembly.
49. 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.
50. Remove the fuel filter bracket to provide a removal path for the fuel and brake line bundle assembly.
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.
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.
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 filter bracket bolt.

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

12. Install the fuel and brake line to the bundle brackets, the length of the vehicle.
13. Install the rear brake line to the bracket bolt above the rear axle assembly.

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

14. Connect the EVAP hose to the rear of the fuel filter.
15. Connect the fuel line to the fuel filter.
16. Install the brake lines to the bundle clips on the right and left frame rails.
17. Install the transmission assembly.
18. Install the transfer case, if equipped.
19. Install the powers steering oil cooler to the mounting bracket.
21. Install the radiator, condenser and transmission oil cooler as an assembly.
22. Raise the vehicle.
23. Install the bolt that secures the power steering to the radiator.

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




24. Connect the center intermediate shaft to the lower intermediate shaft.

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

25. Install the bolt (3) that secures 2 shafts.
26. Working through the left wheelhouse, connect the transmission oil cooler lines near the air conditioning compressor.
27. Working through the right hand wheelhouse, install the bolt which secures the washer fluid reservoir to the front frame brace.

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

28. Install the right and left front wheelhouse liners.
29. Install the right and left wheelhouse splash shields.
30. Install the right and left front tire assemblies.
31. Lower the vehicle.
32. Install the cooling fan.

* Fan Replacement (LH2) Fan Replacement (LY7)
* Engine Cooling Fan Replacement (LH2 Heavy Duty Cooling) Engine Cooling Fan Replacement (LH2 Standard Cooling) Engine Cooling Fan Replacement (LY7)

33. Connect the electrical connector C113 at the right hand frame rail.
34. Connect the electrical connector C5 to the underhood bussed electrical center.
35. Connect the transmission control module.
36. Connect the chassis electrical connector located at the top of the right hand shock tower.
37. Install the positive battery cable to the underhood bussed electrical center.

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

38. 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).

39. Install the underhood electrical center cover.
40. Connect the underhood fuse block connector C5.
41. Connect the front of the dash electrical connector C102.
42. Install the fuel line retainer located on the bracket attached to the heater lines on the front of the dash.
43. Install the brake master cylinder.

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

44. Connect the brake fluid level switch.
45. Connect the brake booster vacuum line to the brake booster.
46. Install the air conditioning liquid line to the condenser.




47. Install the air conditioning suction hose located at the top of the left hand shock tower.
48. Install the air conditioning liquid and suction lines to the retaining feature (1) on the fan shroud.
49. Connect the coolant surge tank hose to the radiator.




50. Install the air cleaner assembly.
51. Install the fuel injector sight shield.
52. Install the cross vehicle brace.
53. Install the positive battery cable.
54. Install the negative battery cable.
55. Remove J 42640.
56. Fill the engine with engine oil.
57. Fill the cooling system.
58. Recharge the air conditioning system.
59. Bleed the brake system.