Removal and Replacement

Engine Replacement

Special Tools

J 41427 Engine Lift Brackets

Removal Procedure




1. Raise the hood to the service position, perform the following:

1. Remove the hood hinge bolts (1).
2. Raise the hood until vertical.
3. Install the hood hinge bolts until snug in the service position (2).

2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (Service and Repair)Battery Negative Cable Disconnection and Connection (TP2) (Service and Repair).
3. Drain the cooling system.
4. Remove the fuel pipes/hoses. Refer to Fuel Line Replacement - Engine (Fuel Line Replacement - Engine).
5. Remove the lower fan shroud. Refer to Engine Coolant Fan Lower Shroud Replacement (Mechanical) (Service and Repair).
6. Remove the drive belt. Refer to Drive Belt Replacement (Service and Repair).
7. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).




8. If equipped, remove the oil pan skid plate bolts and plate.
9. If equipped, remove the engine shield. Refer to Engine Shield Replacement (Engine Shield Replacement).
10. Remove the starter. Refer to Starter Replacement (V8) (Service and Repair)Starter Replacement (V6) (Service and Repair)Starter Replacement (Diesel) (Service and Repair).




11. Remove the transmission cover.




12. Remove the positive battery cable clip bolt (2).
13. Remove the catalytic converter. Refer to Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) (Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp))Catalytic Converter Replacement (LGH /LML) (Catalytic Converter Replacement (LGH /LML))Catalytic Converter Replacement (L96 with E63) (Catalytic Converter Replacement (L96 with E63))Catalytic Converter Replacement (L96 with ZW9) (Catalytic Converter Replacement (L96 with ZW9))Catalytic Converter Replacement (L96 with Exhaust Flange) (Catalytic Converter Replacement (L96 with Exhaust Flange)).




14. Remove the battery cable bracket bolts.




15. Disconnect the crankshaft position (CKP) sensor electrical connector (5) and remove the harness from the retainer clip.
16. Remove the ground bolt (3) holding the negative battery cable (6) and ground cable (4) to the engine.




17. If equipped, remove the torque converter bolts.
18. Remove the transmission bolts.
19. Lower the vehicle.




20. Reposition the radiator inlet hose clamp.
21. Remove the radiator inlet hose from the thermostat housing.




22. Reposition the radiator outlet hose clamps.
23. Remove the radiator outlet hose from the surge tank.
24. Remove the radiator outlet hose from the water pump.




25. Disconnect the following electrical connectors:

* The A/C pressure switch (1), if equipped
* The air conditioning (A/C) compressor clutch (2), if equipped

26. If equipped, remove the air conditioning (A/C) hoses. Refer to Discharge Hose Replacement (LGH, LML) (Discharge Hose Replacement (LGH, LML))Discharge Hose Replacement (LZ1, L20, LC9, L9H, L92) (Discharge Hose Replacement (LZ1, L20, LC9, L9H, L92)) and Suction Hose Replacement (LGH, LML) (Suction Hose Replacement (LGH, LML))Suction Hose Replacement (LZ1, L20, LC9, L9H, L92) (Suction Hose Replacement (LZ1, L20, LC9, L9H, L92)).
27. Remove the positive cable nut and cable from the generator.




28. Remove the engine wiring harness clips (1, 2) from the engine harness brackets.




29. Remove the engine wiring harness rear bracket bolts and bracket.




30. Disconnect the following electrical connectors:

* Evaporative emission (EVAP) canister purge solenoid valve (1)
* Manifold absolute pressure (MAP) sensor

31. Disconnect the engine wiring harness electrical connector (2) from the throttle body.




32. Disconnect the following electrical connectors:

* Knock sensor (1)
* Camshaft position (CMP) sensor (2)
* Fuel pump/oil pressure sensor (3)

33. Remove the harness ground bolt.
34. Reposition the harness ground (4) and ground strap (5).




35. Remove the engine wiring harness bracket bolt (1).
36. Position the engine wiring harness bracket (2) and engine harness aside.




37. Remove the junction block bracket bolt.
38. Reposition the bracket and wiring harness aside.




39. Remove the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve.
40. Remove the stud holding the engine wiring harness bracket.
41. Reposition the engine wiring harness with the bracket aside.
42. Remove the heater hoses. Refer to Heater Inlet Hose Replacement (Non-HP2) (Heater Inlet Hose Replacement (Non-HP2))Heater Inlet Hose Replacement (LGH) (Heater Inlet Hose Replacement (LGH))Heater Inlet Hose Replacement (LML) (Heater Inlet Hose Replacement (LML)) and Heater Outlet Hose Replacement (Non-HP2) (Heater Outlet Hose Replacement (Non-HP2))Heater Outlet Hose Replacement (LGH) (Heater Outlet Hose Replacement (LGH))Heater Outlet Hose Replacement (LML) (Heater Outlet Hose Replacement (LML)).




43. Disconnect the EVAP canister harness (1) from the purge solenoid valve.




44. Disconnect the engine wiring harness electrical connector (7) from the ignition coil.
45. Disconnect the power brake booster vacuum hose from the vacuum fitting.




46. Loosen the power steering (P/S) pump rear bracket nut.
47. Remove the P/S pump rear bracket front nut.
48. Remove the bolts and the nut for the P/S pump bracket.
49. Leave the A/C compressor, if equipped, and the P/S pump on the bracket.
50. Slide the P/S pump bracket forward off the stud and set aside.
51. Remove the thermostat and water outlet. Refer to Engine Coolant Thermostat Replacement (Gas) (Service and Repair)Engine Coolant Thermostat Replacement (Diesel) (Service and Repair).




52. Remove the left front and right rear intake manifold lower bolts.
53. Install J 41427 to the left front and right rear intake manifold bolts, using the following procedure:

1. Install the J 41427 marked RIGHT REAR.
Caution: Refer to Fastener Caution (Fastener Caution).

2. Install the lift bracket bolts.

Tighten the bolts to 15 Nm (11 lb ft).

3. Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of the engine.
4. Install the lift bracket bolts.

Tighten the bolts to 15 Nm (11 lb ft).

54. Install a suitable lifting devise to the engine lift brackets.




55. Remove the engine mount to engine mount bracket nuts.
56. Support the transmission with a suitable floor jack.
57. Remove the engine.

Installation Procedure




1. Install the engine.
Caution: Refer to Fastener Caution (Fastener Caution).

2. Install the engine mount to engine mount bracket bolts.

Tighten the bolts to 65 Nm (48 lb ft).




3. Remove the lifting devise and the J 41427 .
4. Apply threadlock to the threads of the intake manifold lower bolts.
5. Install the intake manifold bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers (Adhesives, Fluids, Lubricants, and Sealers) for the correct part number.

1. Tighten the bolts a first pass to 3 Nm (27 lb in).
2. Tighten the bolts a second pass to 12 Nm (106 lb in).
3. Tighten the bolts a final pass to 15 Nm (11 lb ft).

6. Install one transmission bolt until snug.
7. Remove the support jack from under the transmission.
8. Install the thermostat and water outlet. Refer to Engine Coolant Thermostat Replacement (Gas) (Service and Repair)Engine Coolant Thermostat Replacement (Diesel) (Service and Repair).




9. Slide the P/S pump bracket onto the stud.
10. Install the bolts and the nut for the P/S pump bracket.
11. Install the P/S pump rear bracket front nut.
12. Tighten the P/S pump rear bracket nut.

Tighten the bolts and nuts to 41 Nm (30 lb ft).

13. Connect the power brake booster vacuum hose to the vacuum fitting.




14. Connect the engine wiring harness electrical connector (7) from the ignition coil.




15. Connect the EVAP canister harness (1) to the purge solenoid valve.
16. Install the heater hoses. Refer to Heater Inlet Hose Replacement (Non-HP2) (Heater Inlet Hose Replacement (Non-HP2))Heater Inlet Hose Replacement (LGH) (Heater Inlet Hose Replacement (LGH))Heater Inlet Hose Replacement (LML) (Heater Inlet Hose Replacement (LML)) and Heater Outlet Hose Replacement (Non-HP2) (Heater Outlet Hose Replacement (Non-HP2))Heater Outlet Hose Replacement (LGH) (Heater Outlet Hose Replacement (LGH))Heater Outlet Hose Replacement (LML) (Heater Outlet Hose Replacement (LML)).




17. Position the engine wiring harness.
18. Install the stud holding the engine wiring harness bracket.
19. Install the engine wiring harness rear bracket nut at the EVAP canister purge solenoid valve.

Tighten the nut to 9 Nm (80 lb in).




20. Position the bracket and wiring harness.
21. Install the junction block bracket bolt.

Tighten the bolt to 25 Nm (18 lb ft).




22. Install the engine wiring harness bracket (2).
23. Install the engine wiring harness bracket bolt (1).

Tighten the bolt to 12 Nm (106 lb in).




24. Position the harness ground (4) and ground strap (5).
25. Install the harness ground bolt.

Tighten the bolt to 16 Nm (12 lb ft).

26. Connect the following electrical connectors:

* Knock sensor (1)
* CMP sensor (2)
* Fuel pump/oil pressure sensor (3)




27. Connect the engine wiring harness electrical connector (2) to the throttle body.
28. Connect the following electrical connectors:

* EVAP canister purge solenoid valve (1)
* MAP sensor




29. Place the engine wiring harness rear bracket onto the upper intake manifold and install the bolts.

Tighten the bolts to 10 Nm (89 lb in).




30. Install the engine wiring harness clips (1, 2) to the engine harness brackets.




31. If equipped, install the A/C hoses. Refer to Discharge Hose Replacement (LGH, LML) (Discharge Hose Replacement (LGH, LML))Discharge Hose Replacement (LZ1, L20, LC9, L9H, L92) (Discharge Hose Replacement (LZ1, L20, LC9, L9H, L92)) and Suction Hose Replacement (LGH, LML) (Suction Hose Replacement (LGH, LML))Suction Hose Replacement (LZ1, L20, LC9, L9H, L92) (Suction Hose Replacement (LZ1, L20, LC9, L9H, L92)).
32. Connect the following electrical connectors:

* The A/C compressor clutch (2), if equipped
* The A/C pressure switch (1), if equipped




33. Install the radiator outlet hose to the water pump.
34. Install the radiator outlet hose to the surge tank.
35. Position the radiator outlet hose clamps.




36. Install the radiator inlet hose to the thermostat housing.
37. Position the radiator inlet hose clamp.
38. Install the drive belt. Refer to Drive Belt Replacement (Service and Repair).
39. Install the lower fan shroud. Refer to Engine Coolant Fan Lower Shroud Replacement (Mechanical) (Service and Repair).
40. Install the fuel pipes/hoses. Refer to Fuel Line Replacement - Engine (Fuel Line Replacement - Engine).




41. Remove the hood hinge bolt from the service position (2).
42. Lower the hood to the normal position.
43. Install the hood hinge bolts.

Tighten the bolts to 25 Nm (18 lb ft).

44. Raise the vehicle.




45. Install the transmission bolts.

Tighten the bolts to 50 Nm (37 lb ft).

46. If equipped, install the torque converter bolts.

Tighten the bolts to 63 Nm (47 lb ft).




47. Install the ground bolt (3) holding the negative battery cable (6) and ground cable (4) to the engine.
48. Connect the CKP sensor electrical connector (5) and install the harness to the retainer clip.




49. Install the battery cable bracket bolts.

Tighten the bolts to 12 Nm (106 lb in).

50. Install the catalytic converter. Refer to Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) (Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp))Catalytic Converter Replacement (LGH /LML) (Catalytic Converter Replacement (LGH /LML))Catalytic Converter Replacement (L96 with E63) (Catalytic Converter Replacement (L96 with E63))Catalytic Converter Replacement (L96 with ZW9) (Catalytic Converter Replacement (L96 with ZW9))Catalytic Converter Replacement (L96 with Exhaust Flange) (Catalytic Converter Replacement (L96 with Exhaust Flange)).




51. Install the positive battery cable clip bolt (2).




52. Install the transmission cover.

Tighten the bolts to 12 Nm (106 lb in).

53. Install the starter. Refer to Starter Replacement (V8) (Service and Repair)Starter Replacement (V6) (Service and Repair)Starter Replacement (Diesel) (Service and Repair).
54. If equipped, install the engine shield. Refer to Engine Shield Replacement (Engine Shield Replacement).




55. If equipped, install the oil pan skid plate and bolts.

Tighten the bolts to 20 Nm (15 lb ft).

56. Lower the vehicle.
57. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (Service and Repair)Battery Negative Cable Disconnection and Connection (TP2) (Service and Repair).
58. Perform the engine prelube procedure. Refer to Engine Prelubing (83. Engine Prelubing).
59. Add engine oil supplement to the engine oil. Refer to Adhesives, Fluids, Lubricants, and Sealers (Adhesives, Fluids, Lubricants, and Sealers) for the correct part number.
60. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (Service and Repair)Cooling System Draining and Filling (Static Fill) (Service and Repair)Cooling System Draining and Filling (Static Fill LGH, LML) (Service and Repair).
61. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging (HP2) (Service and Repair)Refrigerant Recovery and Recharging (Non-HP2) (Service and Repair).

Note: After an overhaul, the engine should be tested. Use the following procedure after the engine is installed in the vehicle.

62. Disable the ignition system.
63. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
64. Start the engine and listen for unusual noises.
65. Check the oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
66. If necessary, install an oil pressure gauge and measure the oil pressure.
67. Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.
68. Listen for sticking valve lifters, or other unusual noises.
69. Inspect for fuel, oil, and/or coolant leaks while the engine is running.
70. Perform a final inspection for the proper oil and coolant levels.
71. Close the hood.