Removal

Engine Replacement

Special Tools
* 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.





Note: Do NOT disconnect the battery cables from the engine.

4. Disconnect the negative cable from the battery and the body. Refer to Battery Negative Cable Replacement (LH2 with Top Post) (Battery Negative Cable Replacement (With Top Post))Battery Negative Cable Replacement (LLT With Side Post) (Battery Negative Cable Replacement (With Side Post))Battery Negative Cable Replacement (LLT With Top Post) (Battery Negative Cable Replacement (With Top Post))Battery Negative Cable Replacement (LH2 With Side Post) (Battery Negative Cable Replacement (With Side Post)).
5. Disconnect the positive cable from the battery and the underhood electrical center. Refer to Battery Positive Cable Replacement (LH2 With Top Post) (Battery Positive Cable Replacement (With Top Post))Battery Positive Cable Replacement (LH2 With Side Post) (Battery Positive Cable Replacement (With Side Post))Battery Positive Cable Replacement (LLT With Top Post) (Battery Positive Cable Replacement (With Top Post))Battery Positive Cable Replacement (LLT With Side Post) (Battery Positive Cable Replacement (With Side Post)).
6. Position and secure the battery cables to the engine.
7. Remove the battery. Refer to Battery Replacement (Top Post) (Battery Replacement (Top Post))Battery Replacement (Side Post) (Battery Replacement (Side Post)).
8. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (LLT) (Fuel Injector Sight Shield Replacement).




9. Remove the air cleaner duct. Refer to Air Cleaner Inlet Duct Replacement (Service and Repair).




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 Cooling System Draining and Filling (Static Fill) (Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE 47716) (Cooling System Draining and Filling (GE 47716)).

Note: Do NOT disconnect the surge hoses from the engine or the radiator.

14. Disconnect the surge tank outlet hose from the surge tank. Refer to Radiator Surge Tank Inlet Hose/Pipe Replacement (LH2) (Radiator Surge Tank Inlet Hose/Pipe Replacement)Radiator Surge Tank Inlet Hose/Pipe Replacement (LLT) (Radiator Surge Tank Inlet Hose/Pipe Replacement).
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. Refer to Radiator Surge Tank Outlet Hose/Pipe Replacement (LH2) (Radiator Surge Tank Outlet Hose/Pipe Replacement)Radiator Surge Tank Outlet Hose/Pipe Replacement (LLT) (Radiator Surge Tank Outlet Hose/Pipe Replacement).
17. Position and secure the surge tank inlet hose to the vehicle.
18. Disconnect the heater hoses from the heater core. Refer to Heater Inlet Hose Replacement (LH2) (Heater Inlet Hose Replacement)Heater Inlet Hose Replacement (LLT, LF1) (Heater Inlet Hose Replacement) and to Heater Outlet Hose Replacement (LH2) (Heater Outlet Hose Replacement)Heater Outlet Hose Replacement (LLT, LF1) (Heater Outlet Hose Replacement).




19. Disconnect the purge line (3) from the purge solenoid.
20. Disconnect the fuel pipe (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
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 (Refrigerant Recovery and Recharging).
23. Remove the windshield wiper transmission. Refer to Windshield Wiper Transmission Replacement (Service and Repair).

Note: Do NOT disconnect the suction hose from the A/C compressor.

24. Disconnect the air conditioning suction hose from the evaporator and remove the suction hose bracket from the shock tower. Refer to Air Conditioning Compressor Hose Replacement (LLT) (Air Conditioning Compressor Hose Replacement)Air Conditioning Compressor Hose Replacement (LH2) (Air Conditioning Compressor Hose Replacement).
25. Position and secure the suction hose to the engine.

Note: Do NOT disconnect the liquid line from the condenser.

26. Disconnect the air conditioning pressure switch electrical connector and remove the liquid line. Refer to Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement (LH2) (Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement)Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement (LLT) (Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement).




27. Remove the radiator support bolts.
28. Remove the radiator support brackets.




29. Disconnect the brake booster check valve and vacuum hose (1) from the brake booster (2).
30. Position and secure the brake booster hose to the engine.
31. Disconnect the electrical connector to the brake fluid level switch from the master cylinder.
32. Disconnect the electrical connector to the mass air flow sensor.
33. Unlock and disconnect the instrument panel (I/P) electrical connector from the engine located at the rear of the left bank 2 cylinder head.
34. Position and secure the I/P harness to the vehicle.




35. Disconnect the engine module wiring harness connectors (1-3) from the underhood electrical center. Refer to Underhood Electrical Center or Junction Block Replacement (Removal and Replacement).
36. Disconnect the wiring harness from the transmission control module (TCM).




37. Remove the ground bolt and wire from the longitudinal rail.




38. Unlock and disconnect the front engine wiring harness electrical connector from the engine control module (ECM).




39. Unlock and disconnect the rear engine wiring harness electrical connector from the ECM.




40. Disconnect the engine harness electrical connector at the longitudinal rail.
41. Position and secure the ground wire, the engine harness and the TCM harness to the engine.





Note: Do NOT disconnect the brake pipes from the master cylinder.

42. Remove the master cylinder nuts.
43. Reposition and secure the master cylinder to the engine.
44. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (High Pressure Pump - LLT) (Fuel Pressure Relief (High Pressure Pump))Fuel Pressure Relief (CH 48027 - LP1, LY7) (Fuel Pressure Relief (CH 48027))Fuel Pressure Relief (Without CH 48027 - LY7) (Fuel Pressure Relief (Without CH 48027)).
45. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
46. Remove the muffler assembly. Refer to Exhaust System Replacement (Service and Repair).
47. Remove the propeller shaft. Refer to Rear Propeller Shaft Replacement (All Wheel Drive) (Rear Propeller Shaft Replacement)Rear Propeller Shaft Replacement (Rear Wheel Drive) (Rear Propeller Shaft Replacement).
48. Remove the air deflector. Refer to Front Air Deflector Replacement (Service and Repair).

Note: DO NOT remove the water bottle.

49. Remove the washer bottle bracket. Refer to Windshield Washer Solvent Container Replacement (Without CE4) (Windshield Washer Solvent Container Replacement (Without CE4))Windshield Washer Solvent Container Replacement (With CE4) (Windshield Washer Solvent Container Replacement (With CE4)).
50. Disconnect the side air baffles from the radiator.
51. Disconnect the left front brake pipe retainer along with the brake pipe from the longitudinal rail.
52. Remove the right front brake pipe from the brake pipe bundle retainer.
53. Disconnect the rear brake pipes from the brake pressure modulator valve (BPMV). Refer to Brake Pressure Modulator Valve Replacement (Service and Repair).
54. Plug the brake pipes and the brake modulator valve in order to minimize brake fluid loss.
55. Remove the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (Service and Repair).
56. Remove the lower intermediate steering shaft. Refer to Lower Intermediate Steering Shaft Replacement (without JL7) (Lower Intermediate Steering Shaft Replacement (without JL7))Lower Intermediate Steering Shaft Replacement (With JL7) (Lower Intermediate Steering Shaft Replacement (With JL7)).




57. Remove the lower engine mount nuts. Refer to Engine Mount Replacement - Left Side (Service and Repair) and to Engine Mount Replacement - Right Side (Service and Repair).




58. Disconnect the transmission shift linkage from the transmission.
59. Disconnect the electrical connector to the low oil level sensor.
Secure the electrical connector and the harness to the engine mount bracket.
60. Remove the headlamp leveling sensors. Refer to Headlamp Leveling Front Suspension Height Sensor Replacement (Headlamp Leveling Front Suspension Height Sensor Replacement).
61. Secure the shock modules to the lower control arms with a suitable strap in order to prevent damage to the front brake hoses.




62. Remove the upper mounting bolts from the right and left shock module. Refer to Shock Absorber and Spring Assembly Replacement (Shock Absorber and Spring Assembly Replacement).
63. Raise the vehicle enough to place a suitable lift table under the engine, transmission, front frame and front suspension assembly.
64. Position a suitable powertrain or engine lift table below the frame, engine and transmission.
65. Raise the lift table or lower the vehicle to support the frame, engine and transmission.
66. Remove the bolts which secure the transmission brace to the underbody. Refer to Transmission Support Replacement (Service and Repair).




67. Remove the front frame bolts (2).

Note: Ensure that all the hoses, wires, pipes and shock modules clear the vehicle during the removal process.

68. 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.

Note: Do NOT remove the oxygen sensors.

69. Remove the catalytic converters with the oxygen sensors. Refer to Catalytic Converter Replacement - Left Side (Catalytic Converter Replacement - Left Side) and to Catalytic Converter Replacement - Right Side (Catalytic Converter Replacement - Right Side).
70. Remove the thermostat housing with the heater pipes, heater hoses and surge tank outlet hose. Refer to Engine Coolant Thermostat Housing Removal (9. Engine Coolant Thermostat Housing Removal).
71. Remove the starter motor. Refer to Starter Replacement (LH2) (Service and Repair)Starter Replacement (LLT) (Service and Repair).
72. Remove the flywheel bolts.




73. Remove the heated oxygen sensor (HO2S) connector bracket (1) from the left cylinder head.
74. Remove the engine wiring harness and related components.
75. Disconnect the transmission oil cooler pipes from the engine, radiator and the transmission. Refer to Transmission Fluid Cooler Pipe Replacement - Front (Service and Repair) and to Transmission Fluid Cooler Pipe Replacement - Rear (Service and Repair).
76. Disconnect the radiator hoses from the water outlet housing and the coolant inlet pipe. Refer to Radiator Inlet Hose Replacement (LLT) (Radiator Hose).
77. Disconnect the power steering cooler hoses from the condenser radiator and fan module (CRFM). Refer to Power Steering Cooler Pipe/Hose Replacement (Power Steering Cooler Pipe/Hose Replacement).
78. Plug the power steering hoses and pipes in order to prevent fluid loss and contamination.
79. Remove the CRFM with the radiator hoses from the frame.
80. Install EN 46114 to the engine. Refer to Engine Support Fixture (Engine Support Fixture).
81. Connect a floor crane to the engine lift brackets and raise the floor crane to partially support the engine.
82. Position a second powertrain lift table below the transmission.
83. Remove the bolts that secure the transmission to the engine.
84. Remove the transmission from the engine.
85. Remove the drive belts. Refer to Water Pump and Generator Belt Replacement (Water Pump and Generator Belt Replacement) and to Air Conditioning Compressor and Power Steering Pump Belt Replacement (Air Conditioning Compressor and Power Steering Pump Belt Replacement).
86. Remove the generator and water pump drive belt tensioner. Refer to Drive Belt Tensioner Removal - Right Side (1. Drive Belt Tensioner Removal - Right Side).
87. Remove the A/C compressor and power steering drive belt tensioner. Refer to Drive Belt Tensioner Removal - Left Side (2. Drive Belt Tensioner Removal - Left Side).
88. Remove the generator and the generator bracket. Refer to Starter Replacement (LH2) (Service and Repair)Starter Replacement (LLT) (Service and Repair) and Generator Bracket Replacement (LH2) (Generator Bracket Replacement)Generator Bracket Replacement (LLT) (Generator Bracket Replacement).
89. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement (LH2) (Removal and Replacement)Air Conditioning Compressor Replacement (LLT) (Removal and Replacement).
90. Remove the power steering pump. Refer to Power Steering Pump Replacement (V6) (Power Steering Pump Replacement)Power Steering Pump Replacement (LH2) (Power Steering Pump Replacement).
91. Remove the power steering reservoir from the engine. Refer to Power Steering Fluid Reservoir Replacement (V6) (Service and Repair)Power Steering Fluid Reservoir Replacement (LH2) (Service and Repair).
92. Remove the oil level indicator. Refer to Oil Level Indicator and Tube Removal (3. Oil Level Indicator and Tube Removal).
93. Remove the left exhaust manifold. Refer to Exhaust Manifold Removal - Left Side (4. Exhaust Manifold Removal - Left Side).
94. Remove the oil filter adapter. Refer to Oil Filter Adapter Removal (5. Oil Filter Adapter Removal).
95. Remove the right exhaust manifold. Refer to Exhaust Manifold Removal - Right Side (6. Exhaust Manifold Removal - Right Side).
96. Remove the crankshaft balancer. Refer to Crankshaft Balancer Removal (10. Crankshaft Balancer Removal).
97. Remove the flywheel. Refer to Engine Flywheel Removal (11. Engine Flywheel Removal).
98. Remove the intake manifold. Refer to Intake Manifold Removal (LLT) (7. Intake Manifold Removal).
99. Remove the water outlet. Refer to Water Outlet Removal (8. Water Outlet Removal).
100. Remove the block heater. Refer to Coolant Heater Replacement (LH2, KO5) (Coolant Heater Replacement (K05))Coolant Heater Replacement (LY7, KO5, LLT) (Coolant Heater Replacement (K05)).
101. Remove the ECM with the ECM bracket. Refer to Engine Control Module Replacement (Service and Repair).
102. Use a floor crane in order to remove the engine from the frame.
103. Remove the engine mount brackets with the engine mounts. Refer to Engine Mount Bracket Replacement - Left Side (Engine Mount Bracket Replacement - Left Side) and to Engine Mount Bracket Replacement - Right Side (AWD) (Engine Mount Bracket Replacement - Right Side)Engine Mount Bracket Replacement - Right Side (RWD) (Engine Mount Bracket Replacement - Right Side).