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Removal and Replacement




Engine Replacement

Special Tools

EN-49397 - Engine Lift Bracket Set

For equivalent regional tools, refer to Special Tools (Special Tools).

Removal Procedure

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (Service and Repair)Battery Negative Cable Disconnection and Connection (TP2) (Service and Repair).
2. Drain 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).
3. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement (Service and Repair).
4. Recover the A/C refrigerant. Refer to Refrigerant Recovery and Recharging (HP2) (Service and Repair)Refrigerant Recovery and Recharging (Non-HP2) (Service and Repair).
5. Remove the radiator support. Refer to Radiator Support Replacement (Radiator Support Replacement).
6. Remove the transmission module. Refer to Transmission Control Module Replacement (Allison - Automatic Transmission).
7. Remove the intake manifold upper assembly. Refer to.
8. Remove the air cleaner resonator outlet Duct. Refer to.
9. Remove the air cleaner assembly. Refer to.
10. Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (Non-HP2) (Radiator Hose)Radiator Outlet Hose Replacement (LGH, LML) (Radiator Hose).
11. Remove the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (Non-HP2) (Radiator Hose)Radiator Inlet Hose Replacement (LGH, LML) (Radiator Hose).
12. Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement (LU3) (Air Conditioning Compressor Replacement)Air Conditioning Compressor Replacement (LGH, LML) (Air Conditioning Compressor Replacement)Air Conditioning Compressor Replacement (LZ1, L20, LC9, L9H, L92, LMG) (Air Conditioning Compressor Replacement)Air Conditioning Compressor Replacement (HP2) (Air Conditioning Compressor Replacement)
13. Ensure to reposition the A/C line to the side using mechanics wire.
14. Remove the generator. Refer to Generator Replacement (V6) (Service and Repair)Generator Replacement (V8) (Service and Repair)Generator Replacement (Diesel) (Service and Repair).
15. Remove the power steering pump. Refer to Power Steering Pump Replacement (4.3L) (Power Steering Pump Replacement (4.3L))Power Steering Pump Replacement (4.8L, 5.3L, and 6.2L) (Power Steering Pump Replacement (4.8L, 5.3L, and 6.2L))Power Steering Pump Replacement (L96) (Power Steering Pump Replacement (L96))Power Steering Pump Replacement (6.6L) (Power Steering Pump Replacement (6.6L)).
16. Remove the upper intake tube. Refer to.
17. Disconnect the heater inlet hose. 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)).
18. Disconnect the heater outlet hose. Refer to 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)).
19. Disconnect electrical connector as necessary. Refer to Engine Wiring Harness Assembly Removal (66. Engine Wiring Harness Assembly Removal).
20. Remove the engine ground strap. Refer to Engine Ground Strap Replacement (V6) (Service and Repair)Engine Ground Strap Replacement (V8) (Service and Repair)Engine Ground Strap Replacement (Diesel) (Service and Repair).




21. Install EN-49397 - bracket (1) to the right side exhaust manifold.
22. Install EN-49397 - bracket (2) to the power steering pump mounting bracket.
23. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).




24. Remove the engine shield bolts and shield.
25. Remove the drivetrain and front suspension frame front crossmember. Refer to Drivetrain and Front Suspension Frame Front Crossmember Replacement (1500 Series) (Drivetrain and Front Suspension Frame Front Crossmember Replacement (1500 Series))Drivetrain and Front Suspension Frame Front Crossmember Replacement (2500/3500 Series) (Drivetrain and Front Suspension Frame Front Crossmember Replacement (2500/3500 Series)).
26. If equipped with 4-wheel drive (4WD), remove the front differential carrier assembly. Refer to Differential Carrier Assembly Replacement (1500 4WD) (Differential Carrier Assembly Replacement (1500 4WD))Differential Carrier Assembly Replacement (2500 4WD) (Differential Carrier Assembly Replacement (2500 4WD)).
27. Remove the transmission. Refer to Transmission Replacement (Transmission Replacement).
28. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
29. Install an engine lift chain to the EN-49397 - bracket and attach to an engine lift device.
30. Using the engine lift device, raise the engine only enough to remove the tension from the engine mounts.
31. Remove the left side engine mount center bolt. Refer to Engine Mount Replacement - Left Side (Engine Mount Replacement - Left Side).
32. Remove the right side engine mount center bolt. Refer to Engine Mount Replacement - Right Side (Engine Mount Replacement - Right Side).
33. Carefully raise the engine from the engine compartment on an angle and pull away from the vehicle.

Caution: When replacing a failed engine, clean any engine oil that may have collected in the charge air cooler before installing the new engine. The failure to clean excessive oil from the charge air cooler may cause an engine runaway condition on start up. Engine runaway may result in severe engine damage.

34. Lower the engine on the floor. Ensure to use block of wood to place underneath the oil pan.
35. In order to secure the engine to an engine stand, remove the following:

* Refer to Engine Flywheel Removal (Automatic Transmission) (50. Engine Flywheel Removal (Automatic Transmission)).
* Refer to Exhaust Outlet Removal.
* Refer to Upper Oil Pan Removal (58. Upper Oil Pan Removal).
* Refer to Flywheel Housing Removal (59. Flywheel Housing Removal).
* Refer to Engine Mounting to Stand (60. Engine Mounting to Stand).

36. Transfer parts as necessary.

Installation Procedure

1. Remove the engine from the stand. Refer to Engine Removal from Stand (127. Engine Removal from Stand).
2. Install the following:

* Refer to Engine Flywheel Installation (Automatic Transmission) (136. ngine Flywheel Installation (Automatic Transmission)).
* Refer to Exhaust Outlet Installation.
* Refer to Upper Oil Pan Installation (129. Upper Oil Pan Installation).
* Refer to Flywheel Housing Installation (128. Flywheel Housing Installation).

3. Install the engine in the vehicle. Ensure the engine is angled in order to be installed.
4. With the aid of an assistant, carefully install the engine in the vehicle engine compartment on an angle.
5. Install the left side engine mount center bolt. Refer to Engine Mount Replacement - Left Side (Engine Mount Replacement - Left Side).
6. Install the right side engine mount center bolt. Refer to Engine Mount Replacement - Right Side (Engine Mount Replacement - Right Side).
7. Remove the engine lift chain from the EN-49397 - brackets and attach to an engine lift device.
8. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
9. Install the transmission. Refer to Transmission Replacement (Transmission Replacement).
10. If equipped with 4WD, install the front differential carrier assembly. Refer to Differential Carrier Assembly Replacement (1500 4WD) (Differential Carrier Assembly Replacement (1500 4WD))Differential Carrier Assembly Replacement (2500 4WD) (Differential Carrier Assembly Replacement (2500 4WD)).
11. Install the drivetrain and front suspension frame front crossmember. Refer to Drivetrain and Front Suspension Frame Front Crossmember Replacement (1500 Series) (Drivetrain and Front Suspension Frame Front Crossmember Replacement (1500 Series))Drivetrain and Front Suspension Frame Front Crossmember Replacement (2500/3500 Series) (Drivetrain and Front Suspension Frame Front Crossmember Replacement (2500/3500 Series)).





Caution: Refer to Fastener Caution (Fastener Caution).

12. Install the engine shield and the bolts. Tighten the bolts to 20 Nm (15 lb ft).
13. Connect electrical connector as necessary. Refer to Engine Wiring Harness Assembly Removal (66. Engine Wiring Harness Assembly Removal).
14. Install the engine ground strap. Refer to Engine Ground Strap Replacement (V6) (Service and Repair)Engine Ground Strap Replacement (V8) (Service and Repair)Engine Ground Strap Replacement (Diesel) (Service and Repair).
15. Connect the heater inlet hose. 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)).
16. Connect the heater outlet hose. Refer to 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. Install the upper intake tube. Refer to.
18. Remove the mechanics wire from the A/C line.
19. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement (LU3) (Air Conditioning Compressor Replacement)Air Conditioning Compressor Replacement (LGH, LML) (Air Conditioning Compressor Replacement)Air Conditioning Compressor Replacement (LZ1, L20, LC9, L9H, L92, LMG) (Air Conditioning Compressor Replacement)Air Conditioning Compressor Replacement (HP2) (Air Conditioning Compressor Replacement)
20. Install the generator. Refer to Generator Replacement (V6) (Service and Repair)Generator Replacement (V8) (Service and Repair)Generator Replacement (Diesel) (Service and Repair).
21. Install the power steering pump. Refer to Power Steering Pump Replacement (4.3L) (Power Steering Pump Replacement (4.3L))Power Steering Pump Replacement (4.8L, 5.3L, and 6.2L) (Power Steering Pump Replacement (4.8L, 5.3L, and 6.2L))Power Steering Pump Replacement (L96) (Power Steering Pump Replacement (L96))Power Steering Pump Replacement (6.6L) (Power Steering Pump Replacement (6.6L)).
22. Install the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (Non-HP2) (Radiator Hose)Radiator Outlet Hose Replacement (LGH, LML) (Radiator Hose).
23. Install the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (Non-HP2) (Radiator Hose)Radiator Inlet Hose Replacement (LGH, LML) (Radiator Hose).
24. Install the air cleaner assembly. Refer to.
25. Install the air cleaner resonator outlet duct. Refer to.
26. Install the intake manifold upper assembly. Refer to.
27. Install the radiator support. Refer to Radiator Support Replacement (Radiator Support Replacement).
28. Install the transmission module. Refer to Transmission Control Module Replacement (Allison - Automatic Transmission).
29. 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).
30. Fill the oil system with new oil. Refer to Engine Oil and Oil Filter Replacement (Service and Repair).
31. Recharge the A/C refrigerant. Refer to Refrigerant Recovery and Recharging (HP2) (Service and Repair)Refrigerant Recovery and Recharging (Non-HP2) (Service and Repair).
32. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) (Service and Repair)Battery Negative Cable Disconnection and Connection (TP2) (Service and Repair).

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

33. Test the vehicle using the following procedure:

1. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
2. Start the engine and listen for unusual noises.
3. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
4. Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.
5. Listen for sticking lifter and other unusual noises.
6. Inspect for fuel, oil and/or coolant leaks while the engine is running.

34. Road test the vehicle for normal operation.
35. Inspect for coolant, oil, gas or exhaust leaks.

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