Removal and Replacement
ENGINE - 5.7LREMOVAL
1. Remove the cowl grille (4).
2. Perform the Fuel System Pressure Release procedure.
3. Disconnect the battery negative cable.
4. Remove the air cleaner resonator and duct work as an assembly
5. Drain cooling system.
6. Remove the accessory drive belt.
7. Remove the viscous fan/drive.
8. Remove the upper crossmember and top core support.
9. Remove the condenser.
10. Remove radiator.
11. Evacuate the refrigerant.
12. Remove the A/C compressor (2) with the lines attached. Secure compressor out of the way.
13. Remove generator assembly (2).
14. Remove the intake manifold and IAFM as an assembly.
15. Disconnect the heater hoses.
NOTE: It is not necessary to disconnect P/S hoses from pump, for P/S pump removal.
16. Remove the power steering pump and set aside.
17. Disconnect the fuel supply line.
18. Raise and support the vehicle on a hoist and drain the engine oil.
19. Remove engine front mount thru-bolt nuts (3).
20. Disconnect the transmission oil cooler lines from their retainers at the oil pan bolts.
21. Disconnect exhaust pipe at manifolds.
22. Disconnect the starter wires. Remove starter motor (1).
23. Remove the structural dust cover and transmission inspection cover.
24. Remove drive plate to converter bolts (Automatic transmission equipped vehicles).
25. Remove transmission bell housing to engine block bolts (2).
NOTE: Do not use air tools to install engine lift fixture (2) special tool #8984.
26. Install engine lift fixture (2), special tool #8984. Do not use adapter (4)
27. Separate engine from transmission, remove engine from vehicle, and install engine assembly on a repair stand.
INSTALLATION
NOTE: Do not use air tools to install engine lift fixture (2) special tool #8984.
1. Install engine lift fixture (2), special tool #8984. Do not use adapter (4).
2. Position the engine in the engine compartment.
3. Lower engine into compartment and align engine with transmission.
4. Lower engine assembly until engine mount through bolts rest in mount brackets.
5. Install remaining transmission to engine block mounting bolts (2)and tighten.
6. Tighten engine mount thru bolts (3).
7. Install drive plate to torque converter bolts.
8. Install the structural dust cover.
9. Install the starter (1) and connect the starter wires.
10. Install exhaust pipe to manifold.
11. Remove engine lift fixture (2), special tool #8984.
12. Connect the fuel supply line.
13. Reinstall the power steering pump.
14. Connect the heater hoses.
15. Install the intake manifold.
16. Using a new gasket, install throttle body.
17. Install the generator (2) and wire connections.
18. Install a/c compressor (2) and lines.
19. Install the accessory drive belt.
20. Install radiator.
21. Connect the radiator lower hose.
22. Connect the transmission oil cooler lines to the radiator.
23. Install the fan shroud.
24. Install the fan.
25. Connect the radiator upper hose.
26. Install the condenser.
27. Install upper radiator support crossmember.
28. Install the washer bottle.
29. Charge the refrigerant.
30. Install the cowl grille (4).
31. Install the air cleaner resonator and duct work.
32. Add engine oil to crankcase.
33. Fill cooling system.
34. Connect battery negative cable.
35. Start engine and inspect for leaks.
36. Road test vehicle.