Removal and Replacement

Engine Replacement

Special Tools
* J 38185 - Hose Clamp Pliers.
* EN-49397 - Lift Bracket.

For equivalent regional tools, refer to Special Tools Special Tools

Removal Procedure




1. Remove the air inlet grille (1). Refer to Air Inlet Grille Panel Replacement Service and Repair.
2. Place hood in service position.
3. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) Battery Negative Cable Disconnection and Connection (Single Battery)Battery Negative Cable Disconnection and Connection (TP2) Battery Negative Cable Disconnection and Connection (TP2).
4. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) Cooling System Draining and Filling (Vac-N-Fill)Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (Static Fill LGH, LML) Cooling System Draining and Filling (Static Fill).
5. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement Service and Repair.
6. Recover the A/C refrigerant.




7. Remove the Intake Manifold Tube (5). Refer to Intake Manifold Tube Replacement Intake Manifold Tube Replacement.
8. Remove the EGR cooler. Refer to Exhaust Gas Recirculation Valve Replacement (LGH) Exhaust Gas Recirculation Valve Replacement (LGH)Exhaust Gas Recirculation Valve Replacement (LML) Exhaust Gas Recirculation Valve Replacement (LML).




9. Remove the turbocharger air inlet adapter (2). Refer to Turbocharger Air Inlet Adapter Replacement Turbocharger Air Inlet Adapter Replacement.
10. Remove the water pump outlet pipe bolts. Refer to Water Pump Outlet Pipe Replacement (LGH,LML) Water Pump Outlet Pipe Replacement.




11. Remove the oil cooler adapter nuts (1) and studs (2).




12. Remove the oil cooler bolts (1) and assembly (2).




13. Remove the oil cooler adapter bolts (1) and adapter (2).




14. Remove the upper tie bar (3). Refer to Front End Upper Tie Bar Replacement .




15. Remove radiator support bolts (3). Access the bolts from the rear of the upper radiator support.




16. Remove the compressor discharge hose nut (1) from the condenser.
17. Disconnect the compressor discharge hose (2) from the condenser.




18. Remove the evaporator tube nut (1) from the condenser.
19. Disconnect the evaporator tube (2) from the condenser.
20. Remove the insulator retainer bolts and the upper insulator retainers.
21. Remove the condenser from the vehicle.
22. Remove the transmission fluid auxiliary cooler. Refer to Transmission Fluid Auxiliary Cooler Replacement (Gas) Transmission Fluid Auxiliary Cooler ReplacementTransmission Fluid Auxiliary Cooler Replacement (Diesel) Transmission Fluid Auxiliary Cooler Replacement.
23. Remove the charge air cooler. Refer to Manifold Absolute Pressure Sensor Replacement Service and Repair.
24. Remove the radiator. Refer to Radiator Replacement (4.3L, 4.8L, 5.3L, and 6.0L) Radiator ReplacementRadiator Replacement (LGH, LML) Radiator Replacement.




25. Remove the power steering fluid cooler bolts (2).
26. Remove the power steering fluid cooler (1).
27. Remove the transmission control module.
28. Remove the ECM.




29. Remove the air cleaner outlet duct (2). Refer to Air Cleaner Outlet Duct Replacement Service and Repair.




30. Remove the radiator inlet hose (2). Refer to Radiator Inlet Hose Replacement (Non-HP2) Radiator Inlet Hose ReplacementRadiator Inlet Hose Replacement (LGH, LML) Radiator Inlet Hose Replacement.




31. Reposition the radiator outlet hose clamp (1) at the surge tank usingJ 38185 - Hose Clamp Pliers.
32. Remove the radiator outlet hose (2) from the surge tank.




33. Disconnect the quick connect (1) at the radiator.
34. Reposition the radiator outlet hose clamp (2) at the heater outlet hose usingJ 38185 - Hose Clamp Pliers.
35. Remove the radiator outlet hose clip retainers (3) from the brackets.
36. Remove the radiator outlet hose (4) from the radiator.
37. Remove the radiator outlet hose clamp (1) from the engine.
38. Remove the radiator outlet hose clip retainers (2) from the engine shield.
39. Remove the radiator outlet hose (3). Refer to Radiator Outlet Hose Replacement (Non-HP2) Radiator Outlet Hose ReplacementRadiator Outlet Hose Replacement (LGH, LML) Radiator Outlet Hose Replacement.




40. Remove the air conditioning compressor (2). Refer to Air Conditioning Compressor Replacement (LU3) Removal and ReplacementAir Conditioning Compressor Replacement (LGH, LML) Removal and ReplacementAir Conditioning Compressor Replacement (LZ1, L20, LC9, L9H, L92, LMG) Removal and Replacement.




41. Uncover the B+ terminal (2) by sliding away the protective boot (1).
42. Remove the generator B+ terminal nut (2) and the electrical connector (4).




43. Remove the generator bolts (1) and generator (2) from the generator bracket.
44. If equipped remove the auxiliary generator. Refer to Auxiliary Generator Replacement (KD9) Auxiliary Generator Replacement (KD9).
45. Reposition the power steering pump.
46. Disconnect the heater inlet hose. Refer to Heater Inlet Hose Replacement (Non-HP2) Heater Inlet Hose ReplacementHeater Inlet Hose Replacement (LGH) Heater Inlet Hose Replacement (LGH)Heater Inlet Hose Replacement (LML) Heater Inlet Hose Replacement (LML).
47. Disconnect the heater outlet hose. Refer Heater Outlet Hose Replacement (Non-HP2) Heater Outlet Hose ReplacementHeater Outlet Hose Replacement (LGH) Heater Outlet Hose Replacement (LGH)Heater Outlet Hose Replacement (LML) Heater Outlet Hose Replacement (LML).
48. Disconnect all necessary electrical connections.
49. Remove all ground bolts and wires.
50. Remove the ground strap.




51. Remove the fuel pressure valve bracket bolts (1) and reposition the fuel pressure valve (2).




52. Remove the thermostat bolts (1) from the engine coolant outlet pipe (2).
53. Remove the transmission cooler line retainer bracket on the right side of oil pan and reposition lines.
54. Disconnect fuel feed and return lines.
55. Remove the drivetrain and front suspension frame front crossmember. Refer Drivetrain and Front Suspension Frame Front Crossmember Replacement (2500/3500 Series) Drivetrain and Front Suspension Frame Front Crossmember Replacement (1500 Series) .
56. if equipped remove the front differential carrier assembly. Refer to Differential Carrier Assembly Replacement (2500 4WD) Differential Carrier Assembly Replacement.
57. Remove the transmission. Refer to Transmission Replacement Removal and Replacement.




58. InstallEN-4939 - bracket (1) to the right side exhaust manifold.
59. InstallEN-49397 - bracket (2) to the power steering pump mounting bracket.
60. Attach engine lift device with chains to the engine lift brackets.




61. Remove the left side engine mount bolt (1). Refer to Engine Mount Replacement - Left Side Engine Mount Replacement - Left Side.




62. Remove the right side engine mount bolt (1). Refer to Engine Mount Replacement - Right Side Engine Mount Replacement - Right Side.
63. Remove the engine from vehicle.
64. Transfer parts as necessary.

Installation Procedure

1. Install the engine in the vehicle.




2. Install the right side engine mount bolt (1). Refer to Engine Mount Replacement - Right Side Engine Mount Replacement - Right Side.




3. Install the left side engine mount bolt (1). Refer to Engine Mount Replacement - Left Side Engine Mount Replacement - Left Side.
4. Remove the engine lift chain from the EN-49397 - brackets and attach to an engine lift device.
5. Install the transmission. Refer to Transmission Replacement Removal and Replacement.
6. if equipped Install the front differential carrier assembly. Refer to Differential Carrier Assembly Replacement (2500 4WD) Differential Carrier Assembly Replacement.
7. Install the drivetrain and front suspension frame front crossmember. Refer Drivetrain and Front Suspension Frame Front Crossmember Replacement (2500/3500 Series) Drivetrain and Front Suspension Frame Front Crossmember Replacement (1500 Series) .
8. Connect fuel feed and return lines.





Caution: Refer to Fastener Caution Fastener Caution.

9. Position the thermostat housing (2) and install the bolts (1) and tighten to 25 Nm (17 lb ft).
10. Connect the turbocharger coolant feed pipe retaining bracket bolt. Refer to Turbocharger Coolant Hoses/Pipes Replacement (Feed-LGH/LML) Turbocharger Coolant Hoses/Pipes Replacement (Feed)Turbocharger Coolant Hoses/Pipes Replacement (Return to Turbocharger-LGH/LML) Turbocharger Coolant Hoses/Pipes Replacement (Return to TurbochargerTurbocharger Coolant Hoses/Pipes Replacement (Return to Bypass Pipe-LGH/LML) Turbocharger Coolant Hoses/Pipes Replacement (Return to Bypass Pipe.




11. Position the fuel pressure valve (2) to the thermostat housing and tighten the bolts (1) to 25 Nm (17 lb ft).
12. Connect all ground straps.
13. Connect the heater outlet hose. Refer Heater Outlet Hose Replacement (Non-HP2) Heater Outlet Hose ReplacementHeater Outlet Hose Replacement (LGH) Heater Outlet Hose Replacement (LGH)Heater Outlet Hose Replacement (LML) Heater Outlet Hose Replacement (LML).
14. Connect the heater inlet hose. Refer to Heater Inlet Hose Replacement (Non-HP2) Heater Inlet Hose ReplacementHeater Inlet Hose Replacement (LGH) Heater Inlet Hose Replacement (LGH)Heater Inlet Hose Replacement (LML) Heater Inlet Hose Replacement (LML).
15. Reposition the power steering pump.
16. If equipped Install the auxiliary generator. Refer to Auxiliary Generator Replacement (KD9) Auxiliary Generator Replacement (KD9).




17. Install the generator (2) to the generator bracket and tighten the generator mounting bolts (1) to 50 Nm (37 lb ft).




18. Connect the generator electrical connector (4).
19. Install the battery positive B+ cable terminal (3) to the generator stud and tighten to 10 Nm (89 lb in).
20. Slide the protective boot (1) back onto the terminal stud.




21. Install the air conditioning compressor (2). Refer to Air Conditioning Compressor Replacement (LU3) Removal and ReplacementAir Conditioning Compressor Replacement (LGH, LML) Removal and ReplacementAir Conditioning Compressor Replacement (LZ1, L20, LC9, L9H, L92, LMG) Removal and Replacement.




22. Install the radiator outlet hose (3) to the vehicle.
23. Install the radiator outlet hose clamp (1) to the engine.
24. Install the radiator outlet hose clip retainers (2) to the engine shield.




25. Install the radiator outlet hose (2) to the surge tank.
26. Reposition the radiator outlet hose clamp (1) at the surge tank using J 38185 - Hose Clamp Pliers.




27. Install the radiator inlet hose (2). Refer to Radiator Inlet Hose Replacement (Non-HP2) Radiator Inlet Hose ReplacementRadiator Inlet Hose Replacement (LGH, LML) Radiator Inlet Hose Replacement.




28. Install the air cleaner outlet duct (2). Refer to Air Cleaner Outlet Duct Replacement Service and Repair.
29. Install the ECM. Refer to Engine Control Module Replacement Service and Repair.
30. Install the transmission control module. Refer Transmission Control Module Replacement Service and Repair.




31. Position the power steering fluid cooler (1) in the vehicle.
32. Install the power steering fluid cooler bolts (2) and tighten to 9 Nm (80 lb in).
33. Install the radiator. Refer to Radiator Replacement (4.3L, 4.8L, 5.3L, and 6.0L) Radiator ReplacementRadiator Replacement (LGH, LML) Radiator Replacement.
34. Install the charge air cooler. Refer to Manifold Absolute Pressure Sensor Replacement Service and Repair.
35. Install the transmission fluid auxiliary cooler. Refer to Transmission Fluid Auxiliary Cooler Replacement (Gas) Transmission Fluid Auxiliary Cooler ReplacementTransmission Fluid Auxiliary Cooler Replacement (Diesel) Transmission Fluid Auxiliary Cooler Replacement.




36. Connect the evaporator tube (2) to the condenser using new sealing washers. Refer to Air Conditioning System Seal Replacement Air Conditioning System Seal Replacement.
37. Install the evaporator tube nut (1) to the condenser and tighten to 16 Nm (12 lb ft).




38. Connect the compressor discharge hose (2) to the condenser using new sealing washers. Refer to Air Conditioning System Seal Replacement Air Conditioning System Seal Replacement.
39. Install the compressor discharge hose nut (1) to the condenser and tighten to 16 Nm (12 lb ft).




40. Install radiator support bolts (3). Access the bolts from the rear of the upper radiator support.




41. Install the upper tie bar (3). Refer to Front End Upper Tie Bar Replacement .




42. Install the oil cooler adapter bolts (1) and adapter (2) and tighten to 25 Nm (18 lb ft).




43. Install the oil cooler bolts (1) and oil cooler assembly (2). Tighten the oil cooler assembly bolts to 25 Nm (18 lb ft).




44. Install the oil cooler adapter studs to 10 Nm (89 lb in).
45. Install the oil cooler adapter studs (2) and nut (1) to the flywheel housing and tighten to 25 Nm (18 lb ft).
46. Install the water pump outlet pipe bolts. Refer to Water Pump Outlet Pipe Replacement (LGH,LML) Water Pump Outlet Pipe Replacement.




47. Install the Turbocharger Air Inlet Adapter (2). Refer to Turbocharger Air Inlet Adapter Replacement Turbocharger Air Inlet Adapter Replacement.
48. Install the EGR cooler. Refer to Exhaust Gas Recirculation Valve Replacement (LGH) Exhaust Gas Recirculation Valve Replacement (LGH)Exhaust Gas Recirculation Valve Replacement (LML) Exhaust Gas Recirculation Valve Replacement (LML).




49. Install the Intake Manifold Tube (5). Refer to Intake Manifold Tube Replacement Intake Manifold Tube Replacement.
50. Charge the A/C refrigerant.
51. Fill the engine oil. Refer to Engine Oil and Oil Filter Replacement Service and Repair.
52. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) Cooling System Draining and Filling (Vac-N-Fill)Cooling System Draining and Filling (Static Fill) Cooling System Draining and Filling (Static Fill)Cooling System Draining and Filling (Static Fill LGH, LML) Cooling System Draining and Filling (Static Fill).




53. Install the air inlet grille (1). Refer to Air Inlet Grille Panel Replacement Service and Repair.
54. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (Single Battery) Battery Negative Cable Disconnection and Connection (Single Battery)Battery Negative Cable Disconnection and Connection (TP2) Battery Negative Cable Disconnection and Connection (TP2).
55. Test the vehicle using the following procedure:

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