Engine Replacement

Engine Replacement

Special Tools
* 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. Refer to Front Compartment Sight Shields Replacement (Front Compartment Sight Shields Replacement).
3. Disconnect the positive and negative battery cables from the battery. Refer to Battery Negative Cable Disconnection and Connection (Side Post) (Service and Repair)Battery Negative Cable Disconnection and Connection (LHD With Top Post) (Service and Repair) and Battery Positive Cable Replacement (LH2 With Top Post) (Service and Repair)Battery Positive Cable Replacement (LH2 With Side Post) (Service and Repair)Battery Positive Cable Replacement (LLT With Top Post) (Service and Repair)Battery Positive Cable Replacement (LLT With Side Post) (Service and Repair)Battery Positive Cable Replacement (LC3) (Service and Repair).
4. Remove the cross vehicle brace. Refer to Cross Vehicle Brace Replacement (Cross Vehicle Brace Replacement).
5. Remove the fuel injector sight shield. Refer to Intake Manifold Sight Shield Replacement (Service and Repair).




6. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
7. Remove the supercharger inlet duct assemblies. Refer to Supercharger Inlet Duct Assembly Replacement (Supercharger Inlet Duct Assembly Replacement).
8. Drain the cooling system. Refer to Cooling System Draining and Filling (GE 47716) (Service and Repair)Cooling System Draining and Filling (Static Fill) (Service and Repair).
9. Drain the charge air cooling system. Refer to Charge Air Cooling System Draining and Filling (Static Fill) (Charge Air Cooling System Draining and Filling (Static Fill))Charge Air Cooling System Draining and Filling (Vac N Fill) (Charge Air Cooling System Draining and Filling (Vac N Fill)).
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. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging).
13. Remove the air conditioning liquid line from the vehicle. Refer to Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement (LY7/LLT) (Service and Repair)Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement (LH2) (Service and Repair).
14. Disconnect the air conditioning suction hose from the evaporator core. Refer to Suction Hose Replacement (LY7) (Service and Repair)Suction Hose Replacement (LH2) (Service and Repair).
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. Refer to Fuel Pressure Relief (With CH 48027) (Service and Repair)Fuel Pressure Relief (Without CH 48027) (Service and Repair).
20. Disconnect the fuel line (4) from the fuel rail and position the line to the vehicle. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
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. Refer to Harness Routing Views ([1][2]Harness).
23. Disconnect the underhood fuse block connector C5 located between the right shock tower and the cam cover. Refer to Harness Routing Views ([1][2]Harness).
24. Remove the underhood electrical center cover.




25. Disconnect the battery current sensor electrical connector. Refer to Battery Current Sensor Replacement (Service and Repair).
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. Refer to Underhood Electrical Center or Junction Block Replacement (Service and Repair).
30. Remove the engine cooling fans. Refer to Fan Replacement (LH2 With V92) (Service and Repair).




31. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
32. Remove the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (Service and Repair).
33. Remove the right and left wheelhouse splash shields. Refer to Engine Splash Shield Replacement (STS) (Service and Repair)Engine Splash Shield Replacement (STS-V) (Service and Repair).
34. Remove the right and left wheelhouse liners. Refer to Front Wheelhouse Liner Replacement (Service and Repair).




35. Working through the right wheelhouse opening, remove the windshield washer reservoir brace from the frame and disconnect the chassis wire harness electrical connector. Refer to Harness Routing Views ([1][2]Harness).
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. Refer to Charge Air Cooler Radiator Replacement (Charge Air Cooler Radiator Replacement).
41. Remove the radiator, condenser, and transmission oil cooler as an assembly. Refer to Radiator Replacement (LY7 Standard Cooling) (Service and Repair)Radiator Replacement (LH2 Heavy Duty Cooling) (Service and Repair)Radiator Replacement (LH2 Without V92) (Service and Repair)Radiator Replacement (LLT) (Service and Repair)Radiator Replacement (LC3) (Service and Repair) and Air Conditioning Condenser Replacement (Heavy Duty Cooling) (Service and Repair)Air Conditioning Condenser Replacement (Standard Cooling) (Service and Repair).
42. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
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. Refer to Transmission Replacement (6L50 All Wheel Drive) (Removal and Replacement)Transmission Replacement (6L50 Rear Wheel Drive) (Removal and Replacement)Transmission Replacement (6L80) (Removal and Replacement).
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. Refer to Fuel Filter Replacement (Service and Repair).
48. Disconnect the evaporative emission (EVAP) hose connection from the rear of the fuel filter. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
49. Disconnect the rear brake lines from the bracket above the rear axle assembly on the right side of the vehicle. Refer to Brake Pipe Replacement (Brake Pipe Replacement).
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. Refer to Fuel Line Replacement - Chassis (Service and Repair).
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.

Danger: 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. Refer to Engine Support Fixture (Engine Support Fixture).




65. Install J 28467-87 to the right cylinder head. Refer to Engine Support Fixture (Engine Support Fixture).
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.

Caution: Refer to Fastener Caution (Fastener Caution).

4. Install the frame bolts and tighten to 191 Nm (141 lb ft).




5. Install the right and left upper shock modules bolts then tighten to 112 Nm (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 Lifting and Jacking the Vehicle (Service and Repair).
10. Install the fuel and brake line bundle bracket to the right side wheelhouse then tighten to 9 Nm (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. Refer to Brake Pipe Replacement (Brake Pipe Replacement).
13. Connect the EVAP hose to the rear of the fuel filter. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
14. Connect the fuel feed line to the fuel filter. Refer to Fuel Filter Replacement (Service and Repair).
15. Install the brake lines to the bundle clips on the right and left frame rails.




16. Install the transmission assembly. Refer to Transmission Replacement (6L50 All Wheel Drive) (Removal and Replacement)Transmission Replacement (6L50 Rear Wheel Drive) (Removal and Replacement)Transmission Replacement (6L80) (Removal and Replacement).
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. Refer to Radiator Replacement (LY7 Standard Cooling) (Service and Repair)Radiator Replacement (LH2 Heavy Duty Cooling) (Service and Repair)Radiator Replacement (LH2 Without V92) (Service and Repair)Radiator Replacement (LLT) (Service and Repair)Radiator Replacement (LC3) (Service and Repair) and Air Conditioning Condenser Replacement (Heavy Duty Cooling) (Service and Repair)Air Conditioning Condenser Replacement (Standard Cooling) (Service and Repair).
21. Install the supercharger charge air cooler radiator assembly. Refer to Charge Air Cooler Radiator Replacement (Charge Air Cooler Radiator Replacement).
22. Install the bolt that secures the power steering lines to the radiator and tighten to 9 Nm (80 lb in).




23. Connect the center intermediate shaft to the lower intermediate shaft.
24. Install the bolt (3) that secures 2 shafts and tighten to 30 Nm (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 then tighten to 6 Nm (53 lb in).




27. Install the right and left front wheelhouse liners. Refer to Front Wheelhouse Liner Replacement (Service and Repair).
28. Install the right and left wheelhouse splash shields. Refer to Engine Splash Shield Replacement (STS) (Service and Repair)Engine Splash Shield Replacement (STS-V) (Service and Repair).
29. Install the right and left front tire assemblies. Refer to Tire and Wheel Removal and Installation (Service and Repair).
30. Lower the vehicle.
31. Install the cooling fan. Refer to Fan Replacement (LH2 With V92) (Service and Repair).
32. Connect the engine wire harness C5 connector to the inside of the underhood electrical center. Refer to Underhood Electrical Center or Junction Block Replacement (Service and Repair).
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 and tighten to 15 Nm (11 lb ft).




35. Install the negative battery cable retainer and bolt to the right hand shock tower then tighten to 36 Nm (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. Refer to Harness Routing Views ([1][2]Harness).
40. Connect the charge air cooler reservoir hose to the reservoir.




41. Connect the chassis fuel line (4) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
42. Install the brake master cylinder and tighten to 25 Nm (18 lb ft).
43. Connect the brake fluid level switch.




44. Install the air conditioning liquid and suction lines. Refer to Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement (LY7/LLT) (Service and Repair)Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement (LH2) (Service and Repair) and Suction Hose Replacement (LY7) (Service and Repair)Suction Hose Replacement (LH2) (Service and Repair).
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. Refer to Supercharger Inlet Duct Assembly Replacement (Supercharger Inlet Duct Assembly Replacement).




48. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
49. Install the fuel injector sight shield. Refer to Intake Manifold Sight Shield Replacement (Service and Repair).
50. Install the cross vehicle brace. Refer to Cross Vehicle Brace Replacement (Cross Vehicle Brace Replacement).




51. Install the front engine compartment sight shields. Refer to Front Compartment Sight Shields Replacement (Front Compartment Sight Shields Replacement).
52. Install the positive battery cable. Refer to Battery Positive Cable Replacement (LH2 With Top Post) (Service and Repair)Battery Positive Cable Replacement (LH2 With Side Post) (Service and Repair)Battery Positive Cable Replacement (LLT With Top Post) (Service and Repair)Battery Positive Cable Replacement (LLT With Side Post) (Service and Repair)Battery Positive Cable Replacement (LC3) (Service and Repair).
53. Install the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Side Post) (Service and Repair)Battery Negative Cable Disconnection and Connection (LHD With Top Post) (Service and Repair).
54. Remove the J 42640 steering wheel anti-rotation pin.
55. Fill the engine with engine oil. Refer to Engine Oil and Oil Filter Replacement (Service and Repair).
56. Fill the cooling system. Refer to Cooling System Draining and Filling (GE 47716) (Service and Repair)Cooling System Draining and Filling (Static Fill) (Service and Repair).
57. Fill the charge air cooling system. Refer to Charge Air Cooling System Draining and Filling (Static Fill) (Charge Air Cooling System Draining and Filling (Static Fill))Charge Air Cooling System Draining and Filling (Vac N Fill) (Charge Air Cooling System Draining and Filling (Vac N Fill)).
58. Recharge the air conditioning system. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging).
59. Bleed the brake system. Refer to Hydraulic Brake System Bleeding (Manual) (Service and Repair)Hydraulic Brake System Bleeding (Pressure) (Service and Repair).