Part 1

Engine Replacement

Special Tools
* J 38185 Hose Clamp Pliers
* J 44220 Engine Lift Bracket

Removal Procedure




1. Remove the hood. Refer to Hood Replacement (Service and Repair).
2. Remove the battery box. Refer to Battery Box Replacement (Battery Box Replacement).
3. Remove the left inner wheelhouse liner. Refer to Front Wheelhouse Liner Replacement (Service and Repair).
4. Drain the engine coolant. Refer to Cooling System Draining and Filling (Static Fill) (Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (Vac N Fill) (Cooling System Draining and Filling (Vac N Fill)).
5. Remove the cooling fan. Refer to Fan Replacement (LLV, LLR) (Service and Repair)Fan Replacement (LH9) (Service and Repair).
6. Remove the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement (Air Cleaner Resonator and Outlet Duct Replacement).
7. Remove the A/C compressor from the engine. Position the A/C compressor aside and support it to the vehicle. It is not necessary to discharge the refrigerant. Refer to Air Conditioning Compressor Replacement (LLV, LLR) (Removal and Replacement)Air Conditioning Compressor Replacement (LH9) (Removal and Replacement).
8. Remove the generator. Refer to Generator Replacement (LLV/LLR) (Service and Repair)Generator Replacement (LH8) (Service and Repair).
9. Reinstall the engine lift bracket. Refer to Engine Lift Bracket Replacement (Service and Repair).




10. Use the J 38185 to remove the inlet radiator hose (2) from the thermostat housing (4).
11. Remove the washer solvent container/coolant recovery reservoir mounting bolts ONLY, in order to gain clearance to remove the engine wiring harness. Refer to Windshield Washer Solvent Container Replacement (Service and Repair).




12. Disconnect the 2 engine wiring harness connectors (2) from the powertrain control module (PCM) (3).
13. Disconnect the engine wiring harness retainers (1) from the wheelhouse (4).
14. Open the engine wiring harness retainer (5).




15. Disconnect the engine wiring harness retainers (1) from the power steering pump (2).
16. Disconnect the engine wiring harness connectors from the following components:

* The electric motor actuator connector (4WD only)
* The oil pressure switch




17. Disconnect the engine wiring harness retainer (2) from the camshaft cover (3).
18. Disconnect the engine wiring harness connectors from the following components:

* The exhaust camshaft position (CMP) sensor (5)
* The exhaust camshaft actuator (6)




19. Disconnect the following electrical connectors from the camshaft cover:

* The fuel injector harness (1)
* The heated oxygen sensor (HO2S) (2)
* The engine coolant temperature (ECT) sensor (3)




20. Disconnect the engine wiring harness electrical connectors from the ignition coils.




21. Disconnect the engine wiring harness retainer (3) from the camshaft cover (4).
22. Disconnect the engine wiring harness connector (2) from the throttle body (1).




23. Disconnect the engine wiring harness connector from the intake CMP sensor.




24. Carefully disengage the engine wiring harness conduit from the camshaft cover.
25. Remove the transmission filler tube (M30 only). Refer to Transmission Fluid Filler Tube and Seal Replacement (2.9L, 3.7L) (Service and Repair)Transmission Fluid Filler Tube and Seal Replacement (5.3L) (Service and Repair).
26. Drain the engine oil, if necessary. Refer to Engine Oil and Oil Filter Replacement (Service and Repair).




27. Remove the studs securing the secondary air injection (AIR) pipe cover to the cylinder head.

1. Remove the AIR injection pipe cover studs.
2. Remove the AIR pipe cover and gasket.
3. Discard the gasket.




28. Install the J 44220 in place of the AIR adapter.




29. Disconnect the inlet heater hose quick connect (1) from the heater core (2), and secure to the engine.




30. Remove the power steering pump mounting bolts ONLY, and position aside.




31. Remove the right engine mount-to-frame bracket bolt.




32. Disconnect the engine wiring harness retainer (1) from the intake manifold (2).
33. Position the engine wiring harness aside.
34. Disconnect the fuel feed pipe from the fuel rail. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
35. Disconnect the evaporative emission (EVAP) pipe at the intake manifold. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
36. Remove the oil level indicator and tube. Refer to Oil Level Indicator Tube Replacement (Service and Repair).




37. Disconnect the brake booster hose (6) from the brake booster.
38. Disconnect the manifold absolute pressure (MAP) sensor wiring harness retainer (4) from the intake manifold (5).
39. Raise and support the vehicle only high enough to access the wiring harnesses through the wheelhouse. Refer to Lifting and Jacking the Vehicle (Service and Repair).




40. Disconnect the following wiring harness retainers from the engine wiring harness bracket:

* The battery cable
* The engine wire harness (4, 6)
* The MAP sensor (5)




41. Remove the starter solenoid "S" terminal nut (3) and disconnect the lead (4) from the starter.
42. Remove the starter terminal nut (1) and disconnect the battery positive cable (2) from the starter.




43. Remove the bolt (4) securing the battery negative cable (5) to the engine block (1).




44. Disconnect the engine wiring harness connector from the EVAP canister purge solenoid valve.




45. Disconnect the engine wiring harness connector (3) from knock sensor 2 (1).
46. Disconnect the coolant heater cord from the coolant heater, if equipped.




47. Disconnect the engine wiring harness connector from knock sensor 1 (2).
48. Disconnect the engine wiring harness retainer (4) from the engine oil pan rail.




49. Remove the bolt (5) securing the heater outlet hose/pipe to the left engine mount (4).
50. Remove the heater outlet hose/pipe using J 38185 .




51. Disconnect the engine wiring harness connector (3) from the crankshaft position (CKP) sensor (1).
52. Raise the vehicle completely. Refer to Lifting and Jacking the Vehicle (Service and Repair).
53. Remove the 3 bolts securing the engine wiring ground leads (2) to the engine block.
54. Disconnect the engine wiring harness retainers (5) from the engine oil pan rail.
55. Position the engine wiring harness aside.




56. Remove the left engine mount-to-frame bracket bolt.




57. Remove the nuts securing the fuel hose/pipe brackets to the transmission (MA5 only).




58. Remove the nuts (2) securing the fuel hose/pipe bracket (1) to the transmission (M30 only).
59. Disconnect the fuel hose/pipe retainer (4) from the range selector cable bracket (3), and position aside the fuel hose/pipe bundle (M30 only).
60. Remove the applicable components in order to gain clearance to remove the engine:

* RWD
Remove the crossmember. Refer to Transmission Support Crossmember Replacement (2WD) (Transmission Support Crossmember Replacement)Transmission Support Crossmember Replacement (4WD) (Transmission Support Crossmember Replacement).
* 4WD

1. Remove the front propeller shaft. Refer to Front Propeller Shaft Replacement (Front Propeller Shaft Replacement).




2. Remove the differential carrier assembly bushing to frame bolts ONLY.
3. Position the differential carrier assembly forward.
4. Secure the pinion yoke, in order to prevent the differential carrier from rotating.

61. Disconnect the exhaust and remove the exhaust seal. Refer to Exhaust Seal Replacement (LLV/LLR) (Service and Repair)Exhaust Seal Replacement (LH9) (Service and Repair).




62. Remove the bolt (2) securing the transmission oil cooler pipe bracket to the right side of the engine oil pan rail (M30 only).




63. Remove the inspection plug (3) from the transmission (1) (M30 only).
64. Mark the torque converter to flexplate/flywheel orientation to ensure proper realignment (M30 only).




65. Remove the service slot plug.
66. Repeat the following steps for all 3 torque converter bolts (M30 only):

1. Rotate the harmonic balancer center bolt clockwise ONLY, in order to access the torque converter bolt through the service slot.
2. Remove the torque converter bolt using one of the following:

* 18 mm crowfoot wrench
* Short T50 TORX bit




67. Remove the 9 transmission mounting bolts (2).




68. Remove the remaining transmission mounting bolts (2).
69. Lower the vehicle.
70. Place a jack under the transmission for support.




71. Install an engine lift chain to the engine lift brackets and attach to an engine lift devise.
72. Using the engine lift devise, raise the engine only enough to remove the engine mounts.
73. Remove the bolts securing the following to the engine block:

* The left engine mount
* The right engine mount

74. Position the engine mounts away from the engine.

Note: Ensure clearance is maintained between the engine and the following:

* The A/C compressor
* The A/C hoses
* The engine mounts
* The engine wiring harness
* The fuel hose/pipes
* The heater outlet hose/pipe
* The power steering pump
* The radiator
* The transmission input shaft (MA5 only)
* The transmission oil cooler pipes (M30 only)

75. Carefully raise the engine from the engine compartment, ensuring the transmission stays supported.
76. If equipped with an automatic transmission, remove the automatic transmission flywheel locator. Refer to Flywheel Locator Removal (37. Flywheel Locator Removal).
77. Install the engine to an engine stand.
78. Remove the engine lift chain from the engine lift brackets.