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Engine Replacement




Engine Replacement (LCS) (3.6L Hybrid)

Special Tools

J 39580 Engine Support Table

Removal Procedure

Danger: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure will perform the following tasks:

* Identify how to disable high voltage.
* Identify how to test for the presence of high voltage.
* Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

Failure to follow the procedures exactly as written may result in serious injury or death.

1. Disable the hybrid high voltage system. Refer to High Voltage Disabling (High Voltage Disabling).
2. Disconnect the 12-volt battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (HP5) (Service and Repair).
3. Remove the radiator opening upper cover. Refer to Radiator Opening Upper Cover Replacement (Radiator Opening Upper Cover Replacement).
4. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (LY7) (Service and Repair)Fuel Injector Sight Shield Replacement (LCS) (Service and Repair).
5. Drain the coolant from the generator control module. Refer to Generator Control Module Cooling System Draining and Filling (Generator Control Module Cooling System Draining and Filling).
6. Remove the power inverter module. Refer to Drive Motor Generator Power Inverter Module Removal and Installation (Drive Motor Generator Power Inverter Module Removal and Installation).
7. Remove the engine control module. Refer to Engine Control Module Replacement (Service and Repair).
8. Disconnect the air conditioning evaporator outlet hose. Refer to Evaporator Outlet Hose Replacement (HP5) (Evaporator Outlet Hose Replacement)Evaporator Outlet Hose Replacement (LAT) (Evaporator Outlet Hose Replacement)Evaporator Outlet Hose Replacement (LE5, LZ4, LY7) (Evaporator Outlet Hose Replacement).
9. Disconnect the air conditioning discharge hose from the condenser. Refer to Discharge Hose Replacement (HP5) (Discharge Hose Replacement).
10. Disconnect the air conditioning suction hose. Refer to Suction Hose Replacement (HP5) (Suction Hose Replacement).
11. Disconnect the air conditioning liquid line from the condenser. Refer to Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement (HP5) (Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement)Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement (LAT) (Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement)Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement (LE5, LZ4, LY7) (Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement).
12. Disconnect the fuel lines from the engine. Refer to Fuel Line Replacement - Chassis (Service and Repair).
13. Disconnect the heater hoses from the engine. Refer to Heater Inlet Hose Replacement (HP5) (Service and Repair) and Heater Heater Outlet Hose Replacement (HP5 Pump to Engine) (Service and Repair)Heater Outlet Hose Replacement (HP5 Pump to Heater Core) (Service and Repair).
14. Disconnect all necessary engine electrical connectors. Refer to Harness Routing Views ([1][2]Harness).
15. Remove the left and right powertrain mount bolts.
16. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
17. Drain the engine oil.
18. Remove the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (Service and Repair).
19. Remove the front brake disc calipers from the caliper mounting bracket, then suspend the calipers with mechanics wire or equivalent. DO Not disconnect the brake hoses.
20. Remove the engine splash shields. Refer to Engine Splash Shield Replacement (Service and Repair).
21. Remove the air deflector from the frame. Refer to Front Bumper Fascia Air Deflector Replacement (Front Bumper Fascia Air Deflector Replacement).
22. Remove the front catalytic converters. Refer to Catalytic Converter Replacement - Left Side (LZ4) (Catalytic Converter Replacement - Left Side)Catalytic Converter Replacement - Left Side (LY7 ) (Catalytic Converter Replacement - Left Side)Catalytic Converter Replacement - Left Side (LCS) (Catalytic Converter Replacement - Left Side).
23. Remove the strut to steering knuckle retaining bolts.




24. Disconnect the steering shaft coupling (1) from the steering gear. Refer to Steering Shaft Coupling Replacement (Service and Repair).




25. Disconnect the electrical connectors (1, 2) from the electronic power steering rack motor.
26. Disconnect the out tie rod ends from the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement (Steering Linkage Outer Tie Rod Replacement).
27. Disconnect the stabilizer links from the stabilizer bar. Refer to Stabilizer Shaft Link Replacement (Front Suspension).
28. Remove the steering gear electric motor ground strap from the underbody.




29. Remove the four bolts that attach the electric brake control module (EBCM) (1) to the frame.
30. Support the EBCM with mechanics wire to the vehicle underbody.




31. Lower the vehicle until the frame contacts the J 39580 .




32. Remove the frame reinforcements. Refer to Drivetrain and Front Suspension Frame Reinforcement Replacement (2.4L LE5 and 2.4L LAT) (Service and Repair)Drivetrain and Front Suspension Frame Reinforcement Replacement (3.5L LZ4, 3.6L LY7 and 3.6L LSC) (Service and Repair).
33. Remove the front frame retaining bolts.




34. Raise the vehicle off of the frame with the radiator, condenser, engine, transaxle, power steering rack (1) and stabilizer bar still attached the frame.

Installation Procedure




1. Lower the vehicle on to the frame.

Caution: Refer to Fastener Caution (Fastener Caution).

2. Install the front frame bolts, then tighten the bolts to 155 Nm (114 lb ft).




3. Install the frame reinforcements. Refer to Drivetrain and Front Suspension Frame Reinforcement Replacement (2.4L LE5 and 2.4L LAT) (Service and Repair)Drivetrain and Front Suspension Frame Reinforcement Replacement (3.5L LZ4, 3.6L LY7 and 3.6L LSC) (Service and Repair).
4. Raise the vehicle off of the J 39580 .




5. Install the rear transmission mount to bracket retaining nut, (1) then tighten the nut to 100 Nm (74 lb ft).




6. Install the front transmission mount to frame retaining bolts (1), then tighten the bolts to 76 Nm (56 lb ft) .




7. Install the steering shaft coupling (1) to the steering gear. Refer to Steering Shaft Coupling Replacement (Service and Repair).
8. Install the four EBCM bolts, then tighten the bolts to 40 Nm (30 lb ft).




9. Connect the two electric power steering rack electrical connectors (1, 2).
10. Install the steering gear electric motor ground strap to the underbody.




11. Install the lower ball joints to the steering knuckles. Refer to Lower Control Arm Replacement (Front Suspension).
12. Connect both left and right stabilizer links. Refer to Stabilizer Shaft Insulator Replacement (Front Suspension).
13. Connect the outer tie rod ends to the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement (Steering Linkage Outer Tie Rod Replacement).
14. Install the strut to steering knuckle retaining bolts, then tighten the bolts to 180 Nm (133 lb ft).
15. Install the front brake disc calipers to the caliper mounting bracket, then tighten the bolts to 27 Nm (20 lb ft).
16. Install the front catalytic converters. Refer to Catalytic Converter Replacement - Left Side (LZ4) (Catalytic Converter Replacement - Left Side)Catalytic Converter Replacement - Left Side (LY7 ) (Catalytic Converter Replacement - Left Side)Catalytic Converter Replacement - Left Side (LCS) (Catalytic Converter Replacement - Left Side) and Catalytic Converter Replacement - Right Side (LZ4) (Catalytic Converter Replacement - Right Side)Catalytic Converter Replacement - Right Side (LY7) (Catalytic Converter Replacement - Right Side)Catalytic Converter Replacement - Right Side (LCS) (Catalytic Converter Replacement - Right Side).
17. Connect the fuel lines to the engine. Refer to Fuel Line Replacement - Chassis (Service and Repair).
18. Connect the heater hoses to the engine. Refer to Heater Inlet Hose Replacement (LY7) (Service and Repair)Heater Inlet Hose Replacement (LAT) (Service and Repair)Heater Inlet Hose Replacement (LZ4) (Service and Repair)Heater Inlet Hose Replacement (LE5) (Service and Repair)Heater Inlet Hose Replacement (HP5) (Service and Repair) and Heater Outlet Hose Replacement (LZ4) (Service and Repair)Heater Outlet Hose Replacement (LE5) (Service and Repair)Heater Outlet Hose Replacement (LAT) (Service and Repair)Heater Outlet Hose Replacement (LY7) (Service and Repair)Heater Outlet Hose Replacement (HP5 Pump to Engine) (Service and Repair)Heater Outlet Hose Replacement (HP5 Pump to Heater Core) (Service and Repair).
19. Connect all necessary engine electrical connectors. Refer to Harness Routing Views ([1][2]Harness).
20. Connect the air conditioning evaporator outlet hose. Refer to Evaporator Outlet Hose Replacement (HP5) (Evaporator Outlet Hose Replacement)Evaporator Outlet Hose Replacement (LAT) (Evaporator Outlet Hose Replacement)Evaporator Outlet Hose Replacement (LE5, LZ4, LY7) (Evaporator Outlet Hose Replacement).
21. Connect the air conditioning discharge hose to the condenser. Refer to Discharge Hose Replacement (HP5) (Discharge Hose Replacement).
22. Connect the air conditioning suction hose. Refer to Suction Hose Replacement (HP5) (Suction Hose Replacement).
23. Connect the air conditioning liquid line to the condenser. Refer to Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement (HP5) (Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement)Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement (LAT) (Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement)Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement (LE5, LZ4, LY7) (Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement).
24. Install the engine control module. Refer to Engine Control Module Replacement (Service and Repair).
25. Install the power inverter module. Refer to Drive Motor Generator Power Inverter Module Removal and Installation (Drive Motor Generator Power Inverter Module Removal and Installation).
26. Install the air deflector to the frame. Refer to Front Bumper Fascia Air Deflector Replacement (Front Bumper Fascia Air Deflector Replacement).
27. Install the engine splash shields. Refer to Engine Splash Shield Replacement (Service and Repair).
28. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (Service and Repair).
29. Install the radiator opening upper cover. Refer to Radiator Opening Upper Cover Replacement (Radiator Opening Upper Cover Replacement).
30. Fill the coolant reservoir for the generator control module. Refer Generator Control Module Cooling System Draining and Filling (Generator Control Module Cooling System Draining and Filling).
31. Fill the engine with oil. Refer to Fluid and Lubricant Recommendations (USA and Canada) (Service Intervals).
32. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (LY7) (Service and Repair)Fuel Injector Sight Shield Replacement (LCS) (Service and Repair).
33. Enable the hybrid high voltage system. Refer to High Voltage Enabling (High Voltage Enabling).
34. Connect the 12 volt battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (HP5) (Service and Repair).
35. Check the wheel alignment. Refer to Wheel Alignment Measurement (Service and Repair).

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