Removal and Replacement

Engine Replacement

Special Tools
* J 41798 Engine Lift Bracket
* J 21366 Converter Holding Strap
* J 38185 Hose Clamp Pliers

Removal Procedure




1. Remove the hood. Refer to Hood Replacement (Service and Repair).
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
3. Remove the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (Upper Intake Manifold Sight Shield Replacement).
4. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging).
5. Remove the radiator. Refer to Radiator Replacement (LL8) (Service and Repair)Radiator Replacement (LH6) (Service and Repair).
6. Remove the radiator support brace. Refer to Radiator Support Diagonal Brace Replacement (Service and Repair).
7. Remove the front differential drive axle, if equipped with 4-wheel drive (4WD). Refer to Differential Carrier Assembly Replacement (V8) (Differential Carrier Assembly Replacement).
8. Remove the wheel drive shafts, if equipped with 4-wheel drive. Refer to Wheel Drive Shaft Replacement (Service and Repair).
9. Remove the intake manifold. Refer to Intake Manifold Replacement (5.3L) (Intake Manifold Replacement).
10. Disconnect the following electrical connectors:

* Oil pressure sensor (1)
* Oxygen sensors (2, 3)
* Camshaft position (CMP) sensor (4)




11. Remove the air conditioning (A/C) compressor hose. Refer to Air Conditioning Compressor Hose Replacement (LH6) ()Air Conditioning Compressor Hose Replacement (LL8) ().
12. Disconnect the rear auxiliary A/C compressor pipe fitting (7).
13. Remove the rear auxiliary A/C compressor pipe nut and bolt (2, 5).
14. Tie the pipe assembly out of the way.




15. Disconnect the engine coolant temperature (ECT) sensor (1).
16. Remove the ground terminal bolt (2).
17. Remove the retaining clips from the brackets.




18. Disconnect the A/C pressure switch electrical connector (2).
19. Remove the retaining clip (1) from the cylinder head.
20. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).




21. Remove the ground terminal bolts (2, 4).
22. Remove the starter. Refer to Starter Replacement (5.3L Engine) ()Starter Replacement (4.2L Engine) ().




23. Remove the battery cable channel bolt.
24. Remove the battery cable channel from the oil pan.




25. Disconnect the A/C compressor electrical connector.
26. Lower the vehicle.
27. Gather all branches of the engine wiring harness and reposition the harness off to the side.




28. Remove the generator cable from the generator. Perform the following:

1. Slide the boot down revealing the terminal stud.
2. Remove the generator cable nut from the terminal stud.
3. Remove the generator cable.




29. Remove the generator bracket bolts.
30. Position the bracket with generator aside.




31. Using the J 38185 , remove the inlet hose from the water outlet.




32. Using the J 38185 , remove the outlet hose from the water outlet.




33. Disconnect the auxiliary heater inlet and outlet hose/pipe assembly from the heater water shutoff valve pipes.




34. Using the J 38185 , remove the auxiliary heater inlet and outlet hoses/pipes from the water pump.




35. Remove the ignition coils as required for the proper fit of J 41798 . Refer to Ignition Coil Replacement (Service and Repair).

Caution: Refer to Fastener Caution (Fastener Caution).

36. Install J 41798 .

* Tighten the M8 bolts to 25 Nm (18 ft. lbs.).
* Tighten the M10 bolts to 50 Nm (37 ft. lbs.).

37. Raise the vehicle.
38. Remove the catalytic converter. Refer to Catalytic Converter Replacement (4.2L Engine) ()Catalytic Converter Replacement (5.3L Engine) ().




39. Remove the 3 bracket bolts from both the right and the left sides of the frame engine mount.




40. Remove the torque converter bolts.




41. Remove the transmission oil level indicator tube nut.




42. Remove the transmission oil level indicator tube.




43. Remove the transmission bolt and stud on the right side.




44. Remove the lower transmission bolt/studs.
45. Lower the vehicle.
46. Remove the 3 upper transmission bolts/studs.
47. Install an engine hoist to the J 41798 .
48. Install a floor jack under the transmission for support.
49. Separate the engine from the transmission.
50. Remove the engine.
51. Install the engine to an engine stand.
52. Install the J 21366 .

Installation Procedure




1. Remove the J 21366 .
2. Install an engine hoist to the J 41798 .
3. Remove the engine from the engine stand.
4. Install the engine.
5. Mate the engine to the transmission.
6. Remove the floor jack from under the transmission for support.

Caution: Refer to Fastener Caution (Fastener Caution).

7. Install the 3 upper transmission bolts/studs and tighten to 50 Nm (37 ft. lbs.).
8. Raise the vehicle.
9. Install the lower transmission bolt/studs and tighten to 50 Nm (37 ft. lbs.).




10. Install the transmission bolt and stud on the right side and tighten to 50 Nm (37 ft. lbs.).




11. Install the transmission oil level indicator tube.




12. Install the transmission oil level indicator tube nut and tighten to 10 Nm (89 ft. lbs.).




13. Install the torque converter bolts and tighten to 60 Nm (44 ft. lbs.).




14. Install the 3 bracket bolts to both the right and the left sides of the frame engine mount and tighten to 50 Nm (37 ft. lbs.)
15. Install the catalytic converter. Refer to Catalytic Converter Replacement (4.2L Engine) ()Catalytic Converter Replacement (5.3L Engine) ().
16. Lower the vehicle.




17. Remove J 41798 .
18. Install the ignition coils, as required. Refer to Ignition Coil Replacement (Service and Repair). Tighten the bolts to 8 Nm (71 in. lbs.).




19. Install the auxiliary heater inlet and outlet hoses/pipes to the water pump using the J 38185 .




20. Connect the auxiliary heater inlet and outlet hose/pipe assembly to the heater water shutoff valve pipes.




21. Install the outlet hose to the water outlet using the J 38185 .




22. Install the inlet hose to the water outlet using the J 38185 .




23. Position the bracket with generator to the engine.
24. Install the generator bracket bolts and tighten to 50 Nm (37 ft. lbs.).




25. Install the generator cable to the generator, perform the following procedure:

1. Install the generator cable.
2. Install the generator cable nut to the terminal stud and tighten to 9 Nm (80 in. lbs.).
3. Slide the boot down covering the terminal stud.




26. Gather all branches of the engine wiring harness and position the harness over the engine.
27. Raise the vehicle.
28. Connect the A/C compressor electrical connector.




29. Install the battery cable channel to the oil pan.
30. Install the battery cable channel bolt and tighten to 12 Nm (106 in. lbs.).




31. Install the starter. Refer to Starter Replacement (5.3L Engine) ()Starter Replacement (4.2L Engine) ().
32. Install the ground terminal bolts (2, 4) and tighten to 25 Nm (18 ft. lbs.).
33. Lower the vehicle.




34. Install the retaining clip (1) to the cylinder head.
35. Connect the A/C pressure switch electrical connector (2).




36. Install the retaining clips to the brackets.
37. Install the ground terminal bolt (2) and tighten to 25 Nm (18 ft. lbs.).
38. Connect the ECT sensor (1).




39. Install the rear auxiliary A/C compressor pipe nut and bolt (2, 5) and tighten to 20 Nm (15 ft. lbs.).
40. Connect the rear auxiliary A/C compressor pipe fitting (7). Tighten the nut to 16 Nm (12 ft. lbs.).
41. Install the A/C compressor hose. Refer to Air Conditioning Compressor Hose Replacement (LH6) ()Air Conditioning Compressor Hose Replacement (LL8) ().




42. Connect the following electrical connectors:

* Oil pressure sensor (1)
* Oxygen sensors (2, 3)
* Camshaft position (CMP) sensor (4)

43. Install the intake manifold. Refer to Intake Manifold Replacement (5.3L) (Intake Manifold Replacement).
44. Install the wheel drive shafts. Refer to Wheel Drive Shaft Replacement (Service and Repair).
45. Install the front differential drive axle, if equipped with 4WD. Refer to Differential Carrier Assembly Replacement (V8) (Differential Carrier Assembly Replacement).
46. Install the radiator support brace. Refer to Radiator Support Diagonal Brace Replacement (Service and Repair).
47. Install the radiator. Refer to Radiator Replacement (LL8) (Service and Repair)Radiator Replacement (LH6) (Service and Repair).
48. Recharge the refrigerant. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging).
49. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
50. Prelube the engine. Refer to Engine Prelubing (Engine Prelubing).
51. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn (Procedures).
52. Install the hood. Refer to Hood Replacement (Service and Repair).

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

53. Test the vehicle using the following procedure:

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

54. Install the intake manifold sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (Upper Intake Manifold Sight Shield Replacement).