Part 1

Engine Replacement (5.3L Engine w/RPO HP2)

^ Tools Required
- J 21366 Converter Holding Strap
- J 41798 Engine Lift Bracket
- J 46093 Rotor and Flexplate Holding Tool

Removal Procedure





1. Open the hood.
2. Place the fender covers over both fenders.
3. Raise the hood to the service position. Perform the following procedure:
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).
4. Disconnect the energy storage box (ESB).
5. Remove the engine sight shield.
6. Remove the radiator support.





7. Remove the A/C drive belt.
8. Remove the discharge hose bolt and hose from the compressor.
9. Remove the suction hose bolt and hose from the compressor.
10. Discard the sealing washers. Cap the compressor and line openings.
11. Disconnect the compressor electrical connections.
12. Remove the A/C compressor bolts. The lower right bolt (3) will stay with the compressor due to a lack of clearance.
13. Remove the A/C compressor (2).





14. Open the hose clamp and remove the radiator inlet hose from the water pump.





15. Open the hose clamp and remove the radiator outlet hose from the water pump.
16. Remove the heater hoses.
17. Remove the auxiliary heater water pump.





18. Disconnect the evaporative emission (EVAP) canister purge solenoid (1).
19. Remove the harness bracket nut (2) in order to remove the engine harness from the intake manifold.





20. Disconnect the manifold absolute pressure (MAP) sensor (1) and knock sensor (2) electrical connectors.





21. Remove the connector position assurance (CPA) retainer (1) from the main coil harness connector.
22. Disconnect the main coil harness (4) and fuel injector (2) electrical connectors on the left side.
23. Remove the harness clips (3, 5) from the fuel rail.





24. Remove the CPA retainer (1) from the main coil harness connector.
25. Disengage the CPA retainer on the electronic throttle control (ETC).
26. Disconnect the main coil harness (4), fuel injectors (3), and ETC (2) electrical connectors on the right side.
27. Remove the harness clips (1) from the fuel rail.





28. Remove the engine wiring harness ground bolt (4).
29. Reposition the harness ground (2) and negative battery cable (3) from the block.
30. Disconnect the engine coolant temperature (ECT) sensor (5) electrical connector.





31. Remove the harness ground bolt at the right rear of the engine block.
32. Reposition the harness ground (2) and auxiliary negative battery cable, if equipped, from the block.
33. Remove the harness ground bolt at the left rear of the engine block.
34. Reposition the harness ground, and engine ground strap from the block.
35. Disconnect the following electrical connectors:
^ The oil pressure sensor (1)
^ The camshaft position (CMP) sensor (3)
36. Unclip any missed engine harness clips from the engine.





37. Disconnect the EVAP purge solenoid vent tube from the solenoid (1) and vapor pipe (2).
38. Remove the EVAP tube.
39. Disconnect the fuel feed line.
40. Raise and suitably support the vehicle.



41. Disconnect the following electrical connectors from the engine:
^ The crankshaft position (CKP) sensor (1)
^ The engine oil level sensor (3)
^ The coolant heater, if equipped





42. Remove the battery cable channel bolt.
43. Slide the channel pin out of the oil pan tab.
44. Reposition the lower engine wiring harness off to the side.
45. Lower the vehicle.
46. Reposition the upper portion of the engine wiring harness off to the side.





47. Reposition the vent inlet hose clamp at the throttle body.
48. Remove the radiator vent inlet hose from the throttle body.





49. Remove the 3-phase cable bracket cover bolt (1).





50. Remove the starter/generator control module (SGCM) cover bolts and cover.
51. Remove the 3-phase cable nuts.
52. Remove the 3-phase cable from the SGCM studs.
53. Tie the cable out of the way.





54. Disconnect the engine harness electrical connector (3) from the power steering pump.





55. Remove the power steering pump harness 42-volt connector (5) from the wheelhouse panel.
56. Disconnect the power steering pump harness 42-volt electrical connectors (3, 5).





57. Remove the power steering pump harness bolt (3).
58. Remove the power steering pump harness clip (2) from the bracket.





59. Remove the power steering pump harness clip (1) from the bracket.
60. Remove the ground bolt (3).
61. Disconnect the power steering pump harness electrical connector (4) from the power steering pump.
62. Remove the power steering pump harness from the vehicle.





63. Remove the battery cable clip bolt (1).
64. Remove the battery cable junction block bracket bolts (2) from the power steering pump bracket.





65. Remove the power steering pump bolts (2).
66. Reposition the power steering pump (1) with the lines attached, off to the side.





67. Remove the power steering pump bracket bolts (1, 2) and bracket (3).





68. Remove the vacuum brake booster hose.
69. Remove the ignition coils, as required, for the proper fit of the J 41798 .






70. Notice:
Refer to Fastener Notice in Service Precautions.

Install the J 41798 to the cylinder heads.
^ Tighten the M8 bolts to 25 Nm (18 ft. lbs.).
^ Tighten the M10 bolts to 50 Nm (37 ft. lbs.).





71. Remove the left and right engine mount to engine mount bracket bolts.
72. Raise the vehicle.





73. Remove the engine shield bolts and shield, if equipped.





74. Remove the oil pan skid plate bolts and plate, if equipped.
75. Drain the engine oil.
76. Remove the catalytic converter.





77. Remove the positive battery cable clip bolt and clip.





78. Remove the passenger side closeout cover bolt and cover.






79. Important:
It is highly recommended to use a 3/8 inch, 6-point shallow thin wall socket and a wobble extension to loosen the torque converter bolts, and a 8 mm ball end hex key to remove the bolts, in order to prevent possibly stripping the bolts.

Remove the torque converter bolts.





80. Install J 46093 to the engine block.The flange of J 46093 should locate into a hole in the flexplate. Use 2 M10 1.5 x 40 mm bolts for proper tool operation.
^ Tighten the bolts to 50 Nm (37 ft. lbs.).





81. Remove the transmission oil level indicator tube bolt.





82. Remove the transmission oil level indicator tube from the transmission.





83. Remove the transmission studs (1) and bolts (2).