Removal and Replacement

ENGINE

REMOVAL
1. Disconnect both battery negative cables.
2. Disconnect engine grid heater harness at grid heater relays.
3. Disconnect electrical connections from rear of alternator.
4. Recover A/C refrigerant.
5. Raise vehicle on a hoist.
6. Drain engine coolant.
7. Remove engine oil drain plug and drain engine oil.
8. Remove fan/drive assembly.
9. Remove radiator upper hose.
10. Remove upper fan shroud mounting bolts.
11. Disconnect the coolant recovery bottle hose from the radiator fill neck and remove bottle.
12. Using a 36mm wrench, remove viscous fan/drive assembly.
13. Remove cooling fan and shroud together.
14. Disconnect heater core supply and return hoses from the cylinder head fitting and coolant pipe.
15. Raise vehicle on a hoist.
16. Remove transmission and transfer case (if equipped).
17. Disconnect exhaust pipe from turbocharger extension pipe.
18. Disconnect engine harness to vehicle harness connectors.
19. Remove starter motor.
20. Remove flywheel/flexplate.
21. Remove transmission adapter
22. Disconnect A/C suction/discharge hose from the rear of the A/C compressor.
23. Lower vehicle.
24. Disconnect lower radiator hose from radiator outlet.
25. Automatic transmission models:
26. Disconnect transmission oil cooler lines from in front of radiator using special tool # 6931
27. Remove radiator.
28. If A/C equipped, disconnect A/C condenser refrigerant lines.
29. Disconnect charge air cooler piping.
30. Remove charge air cooler mounting bolts.
31. Remove charge air cooler (and A/C condenser if equipped) from vehicle.
32. Remove damper and speed indicator ring from front of engine.
33. Disconnect engine block heater connector.
34. Disconnect A/C compressor and pressure sensor electrical connectors.
35. Remove the passenger battery ground cable from the engine block. Remove the driver side battery ground cable from the engine block.
36. Remove power steering pump from engine by removing 3 bolts.
37. Remove accelerator linkage cover.
38. Disconnect cables from APPS if early model build
39. If late model build,
40. Disconnect the ECM power connector.
41. Disconnect the ECM ground wire from the hydroform screw.
42. Disconnect the fuel supply and return hoses.
43. Remove the cylinder head cover.
44. Disconnect the 3 injector harness connectors at the rocker housing. Disconnect the wire harnesses from the injectors.
45. Remove the rear engine lift bracket.
46. Remove cylinder # 4, # 5, and # 6 intake and exhaust rocker arms, pedestals, and push tubes. Note the original location for re-assembly.
47. Loosen # 6 fuel line shield bolts and rotate shield out of the way.
48. Remove cylinder # 5 and # 6 high pressure fuel lines. Remove the fuel connector tube nut and fuel connector tube. 46. Remove cylinder # 5 and # 6 fuel injector.
49. Remove rocker housing.





50. Remove two cylinder head bolts in location 4 and 12 according to the diagram and install Tool # 9009 (Fig. 3).
51. Loosen but do not remove engine mount through bolts and nuts.
52. Disconnect hood support struts and position hood out of the way.
53. Attach a chain with two hooks to the engine lift brackets.
54. While keeping engine level, lift straight up out of the mounts.
55. Rotate nose of engine upward and pull out of chassis.

INSTALLATION
1. Remove cylinder head bolts in locations 4 and 12 according to the diagram. Install special Tool 9009.
2. Lower engine into the engine compartment and install the engine the engine mount through bolts and nuts.
3. Tighten the mount through bolts and nuts to 88 Nm (65 ft. lbs.) torque.
4. Remove the engine lifting device (Tool 9009).
5. Check cylinder head capscrew length and install into cylinder head.
6. Torque alternately to 70 Nm (52 ft. lbs.). Torque alternately to 105 Nm (77 ft. lbs.). Rotate 90 degrees.
7. Install rocker housing. Torque to 24 Nm (18 ft. lbs.).
8. Replace injector O-ring and sealing washer on injectors # 5 and # 6. Install injectors and alternately tighten hold-down capscrews to 10 Nm (89 in. lbs.).
9. Install fuel connector tube and fuel connector tube nut. Torque to 50 Nm (37 ft. lbs.).
10. Install # 5 and # 6 high pressure fuel lines. Follow correct torque sequence. Torque fuel line fittings to 30 Nm (22 ft. lbs.). Torque brace capscrew to 24 Nm (18 ft. lbs.).
11. Install rear engine lift bracket. Torque to 77 Nm (57 ft. lbs.).
12. Install push tubes, rocker arms, and pedestals for cylinders # 4, # 5, and # 6. Torque the mounting bolts to 36 Nm (27 ft. lbs.).
13. Reset valve lash on cylinders # 4, # 5, and # 6. Torque adjusting nuts to 24 Nm (18 ft. lbs.).
14. Install cylinder head cover. Torque to 24 Nm (18 ft. lbs.).
15. Connect breather tube and lube oil drain tube to breather housing. Install breather housing. Torque capscrews to 24 Nm (18 ft. lbs.)
16. Connect fuel supply and return hoses.
17. Connect ECM ground to hydroform screw. Connect ECM power connector.
18. Install the APPS cable(s) to the APPS. Install the throttle linkage cover.
19. Install the power steering pump.
20. Install the damper and speed indicator ring. Torque to 40 Nm (30 ft. lbs.) plus 60 degrees.
21. Connect the engine block heater connection.
22. Connect the A/C compressor and pressure sensor connectors
23. Install the charge air cooler and a/c condenser (if equipped). Install and tighten the charge air cooler mounting bolts to 2 Nm (17 in. lbs.).
24. Connect the charge air cooler piping. Torque all clamps to 8 Nm (72 in. lbs.).
25. Connect the a/c refrigerant lines to the a/c condenser (if equipped).
26. Install the radiator upper support panel.
27. Install radiator.
28. Connect the transmission quick-connect oil cooler lines.
29. Raise vehicle.
30. Connect a/c compressor suction/discharge hose (if equipped).
31. Install the radiator lower hose and clamps.
32. Install the battery negative cables to the engine block on the driver and passenger side.
33. Install the transmission adapter with a new camshaft rectangular ring seal. Torque to 77 Nm (57 ft. lbs.).
34. Install the flywheel/flexplate. Torque to 137 Nm (101 ft. lbs.).
35. Install the starter motor. Torque to 43 Nm (32 ft. lbs.).
36. Connect engine to vehicle harness connectors.
37. Install transmission and transfer case (if equipped).
38. Connect the exhaust pipe to the turbocharger elbow.
39. Connect the transmission auxiliary oil cooler lines (if equipped).
40. Lower the vehicle.
41. Connect the heater core supply and return hoses.
42. Install the cooling fan and upper fan shroud at the same time.
43. Install the coolant recovery bottle.
44. Install the windshield washer bottle.
45. Install the upper radiator hose and clamps.
46. Raise vehicle.
47. Connect electronically controlled fan drive wire harness. Install lower radiator fan shroud.
48. Change oil filter and install new engine oil.
49. Fill the cooling system with coolant.
50. Connect grid heater harness at grid heater relays.
51. Connect electrical connections to rear of alternator.
52. Start the engine and inspect for engine oil, coolant, and fuel leaks.