Avalanche, Sierra, Silverado, C&K Series, 1999-2005

Engine 3

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Removal & Installation



6.5L Engine
  1. Drain the cooling system.
  2.  
  3. Discharge the air conditioning system and remove the air conditioning vacuum reservoir.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove or disconnect the following:

    Battery cables
     
    Engine cover, if equipped
     
    Air cleaner
     
    Radiator coolant reservoir bottle
     
    Upper radiator support
     
    Grille and the lower grille valance
     
    Front bumper, if necessary
     
    Air conditioning condenser from in front of the radiator
     
    Radiator hoses at the radiator
     
    Radiator support bracket
     
    Radiator and the shroud
     
    Accelerator and cruise control linkages
     
    Hoses and wires at the fuel unit
     
    Fuel supply unit and cap the lines
     
    Intake manifold
     
    Turbocharger assembly, if equipped
     
    Lower intake manifold, if equipped
     
    Exhaust manifolds, if necessary
     
    Engine wiring harness from the firewall connection
     
    Power steering pump, it's not necessary to disconnect the hoses; just move aside
     
    Heater hoses at the engine
     
    Thermostat housing, if necessary
     
    Oil filler and automatic transmission tubes
     
    Cruise control servo, servo bracket and transducer, if equipped
     
    Exhaust pipes at the manifolds
     
    Driveshaft and plug the end of the transmission
     
    Transmission shift linkage and the speedometer cable
     
    Fuel line from the fuel tank and pump
     
    Transmission mounting bolts
     

  8.  
  9. Support the transmission and engine.

    Click image to see an enlarged view

    Fig. For engine removal and installation, universal lift brackets should be installed in place of the proper intake manifold bolts

  10.  
  11. Install lifting hooks J-41427 as follows:


    1. Remove the 2 right rear lower intake manifold retainers and install lifting hook J-41427 (the one marked -right-). Tighten the bolts to 11 ft. lbs. (15 Nm).
    2.  
    3. Remove the air conditioning compressor and the accessory drive bracket.
    4.  
    5. If equipped, disconnect the EGR tube and the 2 left lower bolts from the intake manifold.
    6.  
    7. Install the lifting hook J-41427 (the one marked -left-) and tighten the bolts to 11 ft. lbs. (15 Nm).
    8.  

  12.  
  13. Remove or disconnect the following:

    Engine mount bracket-to-frame bolts
     
    Engine mount through-bolts
     

  14.  
  15. Raise the engine slightly and remove the engine mounts, support the engine with wood between the oil pan and the crossmember.
  16.  
  17. Remove the manual transmission and clutch as follows:
    1. Remove the clutch housing rear bolts.
    2.  
    3. Remove the bolts attaching the clutch housing to the engine and remove the transmission and clutch as a unit.
      NOTE
      Support the transmission as the last bolt is being removed to prevent damaging the clutch.

    4.  
    5. Remove the starter and clutch housing rear cover.
    6.  
    7. Loosen the clutch mounting bolts a little at a time to prevent distorting the disc until spring pressure is released. Remove all of the bolts, the clutch disc and the pressure plate.
    8.  

  18.  
  19. Remove the automatic transmission as follows:
    1. Lower the engine and support it on blocks.
    2.  
    3. Remove the starter and converter housing cover.
    4.  
    5. Remove the flexplate-to-converter attaching bolts.
    6.  
    7. Support the transmission on blocks.
    8.  
    9. Disconnect the detent cable on the Turbo Hydra-Matic.
    10.  
    11. Remove the transmission-to-engine mounting bolts.
    12.  

  20.  
  21. Attach an engine crane to the engine.
  22.  
  23. Remove the blocks from the engine only and glide the engine away from the transmission.
  24.  

To install:

  1. Install the manual transmission and clutch as follows:
    1. Install the clutch disc and the pressure plate. Tighten the clutch mounting bolts a little at a time to prevent distorting the disc.
    2.  
    3. Install the starter and clutch housing rear cover.
    4.  
    5. Install the bolts attaching the clutch housing to the engine and install the transmission and clutch as a unit. Tighten the bolts to specification.
    6.  
    7. Install the clutch housing rear bolts.
    8.  

  2.  
  3. Install the automatic transmission as follows:
    1. Position the transmission.
    2.  
    3. Install the transmission-to-engine mounting bolts.
    4.  
    5. Connect the throttle linkage and detent cable.
    6.  
    7. Install the flexplate-to-converter attaching bolts. Torque the bolts to 65 ft lbs. (90 Nm).
    8.  
    9. Install the starter and converter housing cover.
    10.  

  4.  
  5. Install or connect the following:

    Engine mount through-bolts and tighten to 50 ft lbs. (68 Nm)
     
    Engine mount bracket-to-frame bolts. Torque the bolts to 44 ft lbs. (59 Nm).
     
    Clutch cross-shaft
     
    Transmission mounting bolts and tighten to 75 ft lbs. (100 Nm)
     
    Transmission shift linkage and the speedometer cable
     
    Driveshaft
     

  6.  
  7. Remove the lifting hooks.

    Compressor
     
    EGR valve tube
     
    Intake manifold retaining bolts
     
    Condenser
     
    Hood latch support
     
    Lower fan shroud and filler panel
     
    Transmission dipstick tube and the accelerator cable at the tube
     
    Coolant hose at the intake manifold and the PCV valve
     
    Cruise control servo, bracket and transducer
     
    Oil filler pipe and automatic transmission filler pipe
     
    Engine dipstick tube
     
    Thermostat housing, if removed
     
    Heater hoses at the engine
     
    Engine wiring harness to the firewall connection
     
    Radiator and the shroud
     
    Radiator support bracket
     
    Exhaust manifolds if removed
     
    Lower intake manifold if removed
     
    Intake manifold
     
    Fuel supply unit
     
    Lines to the fuel supply unit
     
    Accelerator and cruise control linkages
     
    Windshield wiper jar and bracket
     
    Air conditioning condenser
     
    Air conditioning vacuum reservoir, if equipped
     
    Fluid cooler lines at the radiator, if equipped with an automatic transmission
     
    Radiator coolant reservoir bottle
     
    Hoses at the radiator
     
    Upper radiator support
     
    Grille and the lower grille valance
     
    Air cleaner
     
    Air stove pipe
     
    Engine cover
     
    Battery cables
     

  8.  
  9. Refill the cooling system.
  10.  
  11. Recharge the air conditioning system.
  12.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Discharge the air conditioning system and remove the air conditioning vacuum reservoir.
  6.  
  7. Drain the engine oil.
  8.  
  9. Remove or disconnect the following:

    Battery cables
     
    Engine cover, if equipped
     
    Air cleaner
     
    Radiator coolant reservoir bottle
     
    Upper radiator support
     
    Grille and the lower grille valance
     
    Front bumper, if necessary
     
    Air conditioning condenser from in front of the radiator
     
    Radiator hoses at the radiator
     
    Radiator support bracket
     
    Radiator and the shroud
     
    Accelerator and cruise control linkages
     
    Hoses and wires at the fuel unit
     
    Fuel supply unit and cap the lines
     
    Intake manifold
     
    Turbocharger assembly, if equipped
     
    Lower intake manifold, if equipped
     
    Exhaust manifolds, if necessary
     
    Engine wiring harness from the firewall connection
     
    Power steering pump, it's not necessary to disconnect the hoses; just move aside
     
    Heater hoses at the engine
     
    Thermostat housing, if necessary
     
    Oil filler and automatic transmission tubes
     
    Cruise control servo, servo bracket and transducer, if equipped
     
    Exhaust pipes at the manifolds
     
    Driveshaft and plug the end of the transmission
     
    Transmission shift linkage and the speedometer cable
     
    Fuel line from the fuel tank and pump
     
    Transmission mounting bolts
     

  10.  
  11. Support the transmission and engine.

    Click image to see an enlarged view

    Fig. For engine removal and installation, universal lift brackets should be installed in place of the proper intake manifold bolts

  12.  
  13. Install lifting hooks J-41427 as follows:


    1. Step 1: Remove the 2 right rear lower intake manifold retainers and install lifting hook J-41427 (the one marked -right-) Tighten the bolts to 11 ft. lbs. (15 Nm).
    2.  
    3. Step 2: Remove the air conditioning compressor and the accessory drive bracket.
    4.  
    5. Step 3: If equipped, disconnect the EGR tube and the 2 left lower bolts from the intake manifold.
    6.  
    7. Step 4: Install the lifting hook J-41427 (the one marked -left-) and tighten the bolts to 11 ft. lbs. (15 Nm).
    8.  

  14.  
  15. Remove or disconnect the following:

    Engine mount bracket-to-frame bolts
     
    Engine mount through-bolts
     

  16.  
  17. Raise the engine slightly and remove the engine mounts, support the engine with wood between the oil pan and the crossmember.
  18.  
  19. Remove the manual transmission and clutch as follows:
    1. Step 1: Remove the clutch housing rear bolts.
    2.  
    3. Step 2: Remove the bolts attaching the clutch housing to the engine and remove the transmission and clutch as a unit.
      NOTE
      Support the transmission as the last bolt is being removed to prevent damaging the clutch.

    4.  
    5. Step 3: Remove the starter and clutch housing rear cover.
    6.  
    7. Step 4: Loosen the clutch mounting bolts a little at a time to prevent distorting the disc until spring pressure is released. Remove all of the bolts, the clutch disc and the pressure plate.
    8.  

  20.  
  21. Remove the automatic transmission as follows:
    1. Step 1: Lower the engine and support it on blocks.
    2.  
    3. Step 2: Remove the starter and converter housing cover.
    4.  
    5. Step 3: Remove the flexplate-to-converter attaching bolts.
    6.  
    7. Step 4: Support the transmission on blocks.
    8.  
    9. Step 5: Disconnect the detent cable on the Turbo Hydra-Matic.
    10.  
    11. Step 6: Remove the transmission-to-engine mounting bolts.
    12.  

  22.  
  23. Attach an engine crane to the engine.
    1. Step 7: Remove the blocks from the engine only and glide the engine away from the transmission.
    2.  

  24.  

To install:

  1. Install the manual transmission and clutch as follows:
    1. Step 1: Install the clutch disc and the pressure plate. Tighten the clutch mounting bolts a little at a time to prevent distorting the disc.
    2.  
    3. Step 2: Install the starter and clutch housing rear cover.
    4.  
    5. Step 3: Install the bolts attaching the clutch housing to the engine and install the transmission and clutch as a unit. Tighten the bolts to specification.
    6.  
    7. Step 4: Install the clutch housing rear bolts.
    8.  

  2.  
  3. Install the automatic transmission as follows:
    1. Step 1: Position the transmission.
    2.  
    3. Step 2: Install the transmission-to-engine mounting bolts.
    4.  
    5. Step 3: Connect the throttle linkage and detent cable.
    6.  
    7. Step 4: Install the flexplate-to-converter attaching bolts. Torque the bolts to 65 ft lbs. (90 Nm).
    8.  
    9. Step 5: Install the starter and converter housing cover.
    10.  

  4.  
  5. Install or connect the following:

    Engine mount through-bolts. Torque the bolts to 50 ft lbs. (68 Nm).
     
    Engine mount bracket-to-frame bolts. Torque the bolts to 44 ft lbs. (59 Nm).
     
    Clutch cross-shaft
     
    Transmission mounting bolts. Torque the bolts to 75 ft lbs. (100 Nm).
     
    Transmission shift linkage and the speedometer cable
     
    Driveshaft
     

  6.  
  7. Remove the lifting hooks.

    Compressor
     
    EGR valve tube
     
    Intake manifold retaining bolts
     
    Condenser
     
    Hood latch support
     
    Lower fan shroud and filler panel
     
    Transmission dipstick tube and the accelerator cable at the tube
     
    Coolant hose
     
    Cruise control servo, bracket and transducer
     
    Oil filler pipe and automatic transmission filler pipe
     
    Engine dipstick tube
     
    Thermostat housing, if removed
     
    Heater hoses at the engine
     
    Engine wiring harness to the firewall connection
     
    Radiator and the shroud
     
    Radiator support bracket
     
    Exhaust manifolds if removed
     
    Lower intake manifold if removed
     
    Intake manifold
     
    Fuel supply unit
     
    Lines to the fuel supply unit
     
    Accelerator and cruise control linkages
     
    Windshield wiper jar and bracket
     
    Air conditioning condenser
     
    Air conditioning vacuum reservoir, if equipped
     
    Fluid cooler lines at the radiator, if equipped with an automatic transmission
     
    Radiator coolant reservoir bottle
     
    Hoses at the radiator
     
    Upper radiator support
     
    Grille and the lower grille valance
     
    Air cleaner
     
    Air stove pipe
     
    Engine cover
     
    Battery cables
     

  8.  
  9. Refill the cooling system.
  10.  
  11. Recharge the air conditioning system.
  12.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Discharge the air conditioning system and remove the air conditioning vacuum reservoir.
  6.  
  7. Drain the engine oil.
  8.  
  9. Remove or disconnect the following:

    Battery cables
     
    Engine cover, if equipped
     
    Air cleaner
     
    Radiator coolant reservoir bottle
     
    Upper radiator support
     
    Grille and the lower grille valance
     
    Front bumper, if necessary
     
    Air conditioning condenser from in front of the radiator
     

  10.  
  11. If the van is equipped with an automatic transmission, remove the fluid cooler lines from the radiator.

    Radiator hoses at the radiator
     
    Radiator support bracket
     
    Radiator and the shroud
     
    Accelerator and cruise control linkages
     
    Hoses and wires at the fuel unit
     
    Fuel supply unit and cap the lines
     
    Intake manifold
     
    Turbocharger assembly, if equipped
     
    Lower intake manifold, if equipped
     
    Exhaust manifolds, if necessary
     
    Engine wiring harness from the firewall connection
     
    Power steering pump, it's not necessary to disconnect the hoses; just move aside
     
    Heater hoses at the engine
     
    Thermostat housing, if necessary
     
    Oil filler and automatic transmission tubes
     
    Cruise control servo, servo bracket and transducer, if equipped
     
    Exhaust pipes at the manifolds
     
    Driveshaft and plug the end of the transmission
     
    Transmission shift linkage and the speedometer cable
     
    Fuel line from the fuel tank and pump
     
    Transmission mounting bolts
     

  12.  
  13. Support the transmission and engine.

    Click image to see an enlarged view

    Fig. For engine removal and installation, universal lift brackets should be installed in place of the proper intake manifold bolts

  14.  
  15. Install lifting hooks J-41427 as follows:


    1. Step 1: Remove the 2 right rear lower intake manifold retainers and install lifting hook J-41427 (the one marked -right-) Tighten the bolts to 11 ft. lbs. (15 Nm)
    2.  
    3. Step 2: Remove the air conditioning compressor and the accessory drive bracket.
    4.  
    5. Step 3: If equipped, disconnect the EGR tube and the 2 left lower bolts from the intake manifold.
    6.  
    7. Step 4: Install the lifting hook J-41427 (the one marked -left-) and tighten the bolts to 11 ft. lbs. (15 Nm)
    8.  

  16.  
  17. Remove or disconnect the following:

    Engine mount bracket-to-frame bolts
     
    Engine mount through-bolts
     

  18.  
  19. Raise the engine slightly and remove the engine mounts, support the engine with wood between the oil pan and the crossmember.
  20.  
  21. Remove the manual transmission and clutch as follows:
    1. Step 1: Remove the clutch housing rear bolts.
    2.  
    3. Step 2: Remove the bolts attaching the clutch housing to the engine and remove the transmission and clutch as a unit.
      NOTE
      Support the transmission as the last bolt is being removed to prevent damaging the clutch.

    4.  
    5. Step 3: Remove the starter and clutch housing rear cover.
    6.  
    7. Step 4: Loosen the clutch mounting bolts a little at a time to prevent distorting the disc until spring pressure is released. Remove all of the bolts, the clutch disc and the pressure plate.
    8.  

  22.  
  23. Remove the automatic transmission as follows:
    1. Step 1: Lower the engine and support it on blocks.
    2.  
    3. Step 2: Remove the starter and converter housing cover.
    4.  
    5. Step 3: Remove the flexplate-to-converter attaching bolts.
    6.  
    7. Step 4: Support the transmission on blocks.
    8.  
    9. Step 5: Disconnect the detent cable on the Turbo Hydra-Matic.
    10.  
    11. Step 6: Remove the transmission-to-engine mounting bolts.
    12.  

  24.  
  25. Attach an engine crane to the engine.
    1. Step 7: Remove the blocks from the engine only and glide the engine away from the transmission.
    2.  

  26.  

To install:

  1. Install the manual transmission and clutch as follows:
    1. Step 1: Install the clutch disc and the pressure plate. Tighten the clutch mounting bolts a little at a time to prevent distorting the disc.
    2.  
    3. Step 2: Install the starter and clutch housing rear cover.
    4.  
    5. Step 3: Install the bolts attaching the clutch housing to the engine and install the transmission and clutch as a unit. Tighten the bolts to specification.
    6.  
    7. Step 4: Install the clutch housing rear bolts.
    8.  

  2.  
  3. Install the automatic transmission as follows:
    1. Step 1: Position the transmission.
    2.  
    3. Step 2: Install the transmission-to-engine mounting bolts.
    4.  
    5. Step 3: Connect the throttle linkage and detent cable.
    6.  
    7. Step 4: Install the flexplate-to-converter attaching bolts. Torque the bolts to 65 ft lbs. (90 Nm).
    8.  
    9. Step 5: Install the starter and converter housing cover.
    10.  

  4.  
  5. Install or connect the following:

    Engine mount through-bolts. Torque the bolts to 50 ft lbs. (68 Nm)
     
    Engine mount bracket-to-frame bolts. Torque the bolts to 44 ft lbs. (59 Nm)
     
    Clutch cross-shaft
     
    Transmission mounting bolts. Torque the bolts to 75 ft lbs. (100 Nm)
     
    Transmission shift linkage and the speedometer cable.
     
    Driveshaft
     

  6.  
  7. Remove the lifting hooks.

    Compressor
     
    EGR valve tube
     
    Intake manifold retaining bolts
     
    Condenser
     
    Hood latch support
     
    Lower fan shroud and filler panel
     
    Transmission dipstick tube and the accelerator cable at the tube
     
    Coolant hose at the intake manifold and the PCV valve
     
    Distributor cap
     
    Cruise control servo, bracket and transducer
     
    Oil filler pipe and automatic transmission filler pipe
     
    Engine dipstick tube
     
    Thermostat housing, if removed
     
    Heater hoses at the engine
     
    Engine wiring harness to the firewall connection
     
    Radiator and the shroud
     
    Radiator support bracket
     
    Exhaust manifolds if removed
     
    Lower intake manifold if removed
     
    Intake manifold
     
    Fuel supply unit
     
    Lines to the fuel supply unit
     
    Accelerator and cruise control linkages
     
    Windshield wiper jar and bracket
     
    Air conditioning condenser
     
    Air conditioning vacuum reservoir, if equipped
     
    Fluid cooler lines at the radiator, if equipped with an automatic transmission
     
    Radiator coolant reservoir bottle
     
    Hoses at the radiator
     
    Upper radiator support
     
    Grille and the lower grille valance
     
    Air cleaner
     
    Air stove pipe
     
    Engine cover
     
    Battery cables
     

  8.  
  9. Refill the cooling system.
  10.  
  11. Recharge the air conditioning system.
  12.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Discharge the air conditioning system and remove the air conditioning vacuum reservoir.
  6.  
  7. Drain the engine oil.
  8.  
  9. Remove or disconnect the following:

    Battery cables
     
    Engine cover, if equipped
     
    Air cleaner
     
    Radiator coolant reservoir bottle
     
    Upper radiator support
     
    Grille and the lower grille valance
     
    Front bumper, if necessary
     
    Air conditioning condenser from in front of the radiator
     

  10.  
  11. If the van is equipped with an automatic transmission, remove the fluid cooler lines from the radiator.

    Radiator hoses at the radiator
     
    Radiator support bracket
     
    Radiator and the shroud
     
    Accelerator and cruise control linkages
     
    Hoses and wires at the fuel unit
     
    Fuel supply unit and cap the lines
     
    Intake manifold
     
    Turbocharger assembly, if equipped
     
    Lower intake manifold, if equipped
     
    Exhaust manifolds, if necessary
     
    Engine wiring harness from the firewall connection
     
    Power steering pump, it's not necessary to disconnect the hoses; just move aside
     
    Heater hoses at the engine
     
    Thermostat housing, if necessary
     
    Oil filler and automatic transmission tubes
     
    Cruise control servo, servo bracket and transducer, if equipped
     
    Exhaust pipes at the manifolds
     
    Driveshaft and plug the end of the transmission
     
    Transmission shift linkage and the speedometer cable
     
    Fuel line from the fuel tank and pump
     
    Transmission mounting bolts
     

  12.  
  13. Support the transmission and engine.

    Click image to see an enlarged view

    Fig. For engine removal and installation, universal lift brackets should be installed in place of the proper intake manifold bolts

  14.  
  15. Install lifting hooks J-41427 as follows:


    1. Step 1: Remove the 2 right rear lower intake manifold retainers and install lifting hook J-41427 (the one marked -right-) Tighten the bolts to 11 ft. lbs. (15 Nm)
    2.  
    3. Step 2: Remove the air conditioning compressor and the accessory drive bracket.
    4.  
    5. Step 3: If equipped, disconnect the EGR tube and the 2 left lower bolts from the intake manifold.
    6.  
    7. Step 4: Install the lifting hook J-41427 (the one marked -left-) and tighten the bolts to 11 ft. lbs. (15 Nm)
    8.  

  16.  
  17. Remove or disconnect the following:

    Engine mount bracket-to-frame bolts
     
    Engine mount through-bolts
     

  18.  
  19. Raise the engine slightly and remove the engine mounts, support the engine with wood between the oil pan and the crossmember.
  20.  
  21. Remove the manual transmission and clutch as follows:
    1. Step 1: Remove the clutch housing rear bolts.
    2.  
    3. Step 2: Remove the bolts attaching the clutch housing to the engine and remove the transmission and clutch as a unit.
      NOTE
      Support the transmission as the last bolt is being removed to prevent damaging the clutch.

    4.  
    5. Step 3: Remove the starter and clutch housing rear cover.
    6.  
    7. Step 4: Loosen the clutch mounting bolts a little at a time to prevent distorting the disc until spring pressure is released. Remove all of the bolts, the clutch disc and the pressure plate.
    8.  

  22.  
  23. Remove the automatic transmission as follows:
    1. Step 1: Lower the engine and support it on blocks.
    2.  
    3. Step 2: Remove the starter and converter housing cover.
    4.  
    5. Step 3: Remove the flexplate-to-converter attaching bolts.
    6.  
    7. Step 4: Support the transmission on blocks.
    8.  
    9. Step 5: Disconnect the detent cable on the Turbo Hydra-Matic.
    10.  
    11. Step 6: Remove the transmission-to-engine mounting bolts.
    12.  

  24.  
  25. Attach an engine crane to the engine.
    1. Step 7: Remove the blocks from the engine only and glide the engine away from the transmission.
    2.  

  26.  

To install:

  1. Install the manual transmission and clutch as follows:
    1. Step 1: Install the clutch disc and the pressure plate. Tighten the clutch mounting bolts a little at a time to prevent distorting the disc.
    2.  
    3. Step 2: Install the starter and clutch housing rear cover.
    4.  
    5. Step 3: Install the bolts attaching the clutch housing to the engine and install the transmission and clutch as a unit. Tighten the bolts to specification.
    6.  
    7. Step 4: Install the clutch housing rear bolts.
    8.  

  2.  
  3. Install the automatic transmission as follows:
    1. Step 1: Position the transmission.
    2.  
    3. Step 2: Install the transmission-to-engine mounting bolts.
    4.  
    5. Step 3: Connect the throttle linkage and detent cable.
    6.  
    7. Step 4: Install the flexplate-to-converter attaching bolts. Torque the bolts to 65 ft lbs. (90 Nm).
    8.  
    9. Step 5: Install the starter and converter housing cover.
    10.  

  4.  
  5. Install or connect the following:

    Engine mount through-bolts. Torque the bolts to 50 ft lbs. (68 Nm)
     
    Engine mount bracket-to-frame bolts. Torque the bolts to 44 ft lbs. (59 Nm)
     
    Clutch cross-shaft
     
    Transmission mounting bolts. Torque the bolts to 75 ft lbs. (100 Nm)
     
    Transmission shift linkage and the speedometer cable.
     
    Driveshaft
     

  6.  
  7. Remove the lifting hooks.

    Compressor
     
    EGR valve tube
     
    Intake manifold retaining bolts
     
    Condenser
     
    Hood latch support
     
    Lower fan shroud and filler panel
     
    Transmission dipstick tube and the accelerator cable at the tube
     
    Coolant hose at the intake manifold and the PCV valve
     
    Distributor cap
     
    Cruise control servo, bracket and transducer
     
    Oil filler pipe and automatic transmission filler pipe
     
    Engine dipstick tube
     
    Thermostat housing, if removed
     
    Heater hoses at the engine
     
    Engine wiring harness to the firewall connection
     
    Radiator and the shroud
     
    Radiator support bracket
     
    Exhaust manifolds if removed
     
    Lower intake manifold if removed
     
    Intake manifold
     
    Fuel supply unit
     
    Lines to the fuel supply unit
     
    Accelerator and cruise control linkages
     
    Windshield wiper jar and bracket
     
    Air conditioning condenser
     
    Air conditioning vacuum reservoir, if equipped
     
    Fluid cooler lines at the radiator, if equipped with an automatic transmission
     
    Radiator coolant reservoir bottle
     
    Hoses at the radiator
     
    Upper radiator support
     
    Grille and the lower grille valance
     
    Air cleaner
     
    Air stove pipe
     
    Engine cover
     
    Battery cables
     

  8.  
  9. Refill the cooling system.
  10.  
  11. Recharge the air conditioning system.
  12.  

6.6L Engine

NOTE
In order to remove the engine, the vehicle must be on a lift. the front tires also need to be removed. You will have to support the vehicle by its frame for tire removal.

  1. Drain the cooling system.
  2.  
  3. Discharge and recover the air conditioning system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Raise the hood to the servicing position. Move the hood hinge bolt to hold the hood in the servicing position.
  8.  
  9. Disconnect the battery cables.
  10.  
  11. Remove the upper intake manifold sight shield as follows:
    1. Remove the retaining bolt in the front of the shield.
    2.  
    3. Lift up on the front of the shield, then left the shield off the rear bracket.
    4.  

  12.  
  13. Remove or disconnect the following:
    NOTE
    After you remove the duct, cover the turbocharger openings and ducts with tape to prevent foreign objects from entering.






    Air cleaner outlet duct from the air cleaner and turbocharger.
     
    Mass Air Flow (MAF) switch connector
     
    A/C pressure cycling switch connector
     
    Surge tank switch
     
    Engine wire harness clip from the accumulator
     
    Engine wire harness clips from the wheelhouse inner panel and engine bracket
     
    Air cleaner assembly and bracket
     
    Surge tank
     

  14.  
  15. Raise the vehicle.

    Front tires and wheels
     
    Both front fender wheelhouse inner panels
     

  16.  
  17. Lower the vehicle.

    Charged air cooler pipes and hoses from the engine and charged air cooler
     
    Radiator inlet hose form the radiator and engine
     
    Upper and lower fan shrouds
     
    Radiator outlet hose from the radiator
     
    Outlet heater hose from the outlet radiator hose
     
    Hose clips from the frame
     
    Radiator outlet hose from the engine
     
    Bolt securing the outlet heater hose pipe to the alternator mounting bracket
     
    Nut securing the outlet heater hose pipe to the fuel filter mounting bracket
     
    Secure the heater hose aside
     
    Upper radiator support
     
    Radiator
     
    Charged air cooler
     
    A/C condenser
     
    Alternator harness connector
     
    A/C refrigerant switch connector
     
    Dual alternator harness connector, if equipped
     
    A/C compressor clutch connector
     
    Harness clip from the A/C compressor bracket
     
    Battery cable from the alternator and auxiliary alternator, if equipped
     
    Battery cable harness clips from the bracket
     
    Bolt securing the battery cable junction block from the power steering pump
     
    Move and secure the battery cables aside
     
    Both fuel injection control module harness connectors, by flipping the latch up
     
    Engine wire harness from the retainer
     
    Fuel lines at the engine
     
    Remove the nut and the fuel line bracket from the upper valve rocker arm cover stud
     
    Fuel lines aside
     
    Power supply cable from the glow plug relay
     
    Drive belt
     
    Suction hose from the accumulator. You can leave the compressor end on the compressor.
     
    A/C compressor bolts, then move the compressor, with the hoses attached, to the right side of the engine compartment
     
    Wiring harness to the left side of the engine and tie aside
     
    Bolts holding the power steering pump front bracket to the pump and A/C compressor mounting bracket
     
    A/C compressor and power steering pump bracket. Once the battery cables are removed from the engine, the power steering pump can be removed further out of the way
     
    Positive Crankcase Ventilation (PCV) oil separator from the bracket
     
    Bolts securing the PCV separator bracket and fuel bleed valve
     
    Right idler pulley (ribbed)
     
    Alternator mounting bracket and secure aside. You do not have to remove the alternator or the belt tensioner
     
    Inlet heater hose from the heater core inlet, using Quick Connect-Disconnect tool No. J 43181
     
    Bolt and ground wires from the rear of the left cylinder head
     

  18.  
  19. Raise the vehicle

    Oil pan skid plate
     
    Engine protection shield, if equipped
     
    Bolt for the negative battery cable and engine wiring harness ground wire from the left side of the engine
     
    Bolts holding the battery cable channel retainer to the lower crankcase
     
    Engine coolant heater cord
     
    Starter motor
     
    Nut securing the battery cable bracket to the right side of the lower crankcase
     
    Bolt holding the auxiliary negative battery cable and the engine wiring harness ground wires to the right side of the engine
     
    Position the battery cables aside
     
    Exhaust pipe-to-exhaust outlet clamp
     
    Lower oil pan, if 4WD
     

  20.  
  21. If equipped with an automatic transmission, matchmark the installed position of the flywheel and torque converter.

    Torque converter bolts through the starter opening
     
    Transmission oil line clip nut if equipped with A/T
     
    Nuts securing the transmission fluid fill tube bracket, if equipped with A/T
     
    Transmission-to-engine stud and bolts. Note the location of the studs and any brackets attached to the studs
     

  22.  
  23. Lower the vehicle to work through the wheel opening

    Engine mount-to-frame bracket bolts
     

  24.  
  25. Lower the vehicle.
  26.  
  27. Install Engine Lifting Bracket tool No. J 36857 to the rear of the left cylinder head with a suitable bolt.
  28.  
  29. Install Engine Lifting Bracket tool No. J 36857 to the front of the right cylinder head with a suitable bolt.
  30.  
  31. Install a suitable lifting device. The engine will have to be angled to remove it. Use a load positioning sling to help in angling the engine.
  32.  
  33. Raise the vehicle off the engine mounts.
  34.  
  35. Remove the left and right engine mount frame brackets.
  36.  
  37. Remove the engine assembly from the vehicle.
  38.  
  39. Secure the engine on an engine stand by removing the following components:

    Flywheel/flexplate
     
    Rear main seal
     
    Exhaust outlet
     
    Oil pan
     
    Flywheel housing
     

  40.  

To install:

  1. Install Engine Lifting Bracket tool No. J 36857 to the rear of the left cylinder head with a suitable bolt.

    Click image to see an enlarged view

    Fig. Install the engine lifting bracket to the rear of the left cylinder head

  2.  
  3. Install Engine Lifting Bracket tool No. J 36857 to the front of the right cylinder head with a suitable bolt.
  4.  
  5. Install a suitable lifting device. The engine will have to be angled to install it. Use a load positioning sling to help in angling the engine.
  6.  
  7. Install or connect the following:

    Engine in the vehicle
     
    2 transmission-to-engine bolts, loosely
     
    Left and right side engine mount frame brackets and tighten to 55 ft. lbs. (75 Nm)
     
    Engine mount-to-frame bracket bolts and tighten to 50 ft. lbs. (65 Nm)
     

  8.  
  9. Remove the lifting brackets from the cylinder heads.

    Transmission-to-engine bolts/studs and tighten to 37 ft. lbs. (50 Nm)

    Click image to see an enlarged view

    Fig. Transmission-to-engine mounting-6.6L engine with A/T

     
    Torque converter bolts and tighten to 44 ft. lbs. (60 Nm)
     

  10.  
  11. Install the remaining components in the reverse of the removal procedure, noting the following important specifications and steps:

    Transmission fluid tube bracket nuts: 13 ft. lbs. (18 Nm)
     
    Transmission oil cooler line clip bolt: 80 inch lbs. (9 Nm)
     
    Exhaust pipe clamp: 30 ft. lbs. (40 Nm)
     
    Ground wire bolt: 25 ft. lbs. (34 Nm)
     
    Battery cable bracket bolts: 106 inch lbs. (12 Nm)
     
    Cable and ground wire bolts: 25 ft. lbs. (34 Nm)
     
    Oil pan skid plate bolts: 15 ft. lbs. (20 Nm)
     
    Engine protection shield bolts: 15 ft. lbs. (20 Nm)
     
    Alternator bracket bolt: 37 ft. lbs. (50 Nm)
     
    Idler pulley bolt: 32 ft. lbs. (43 Nm)
     
    A/C compressor bolts: 37 ft. lbs. (50 Nm)
     

  12.  
  13. Refill the crankcase and the cooling system.
  14.  
  15. Recharge the air conditioning system.
  16.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    NOTE
    In order to remove the engine, the vehicle must be on a lift. the front tires also need to be removed. You will have to support the vehicle by it-s frame for tire removal.

  2.  
  3. Drain the cooling system.
  4.  
  5. Discharge and recover the air conditioning system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Raise the hood to the servicing position. Move the hood hinge bolt to hold the hood in the servicing position.
  10.  
  11. Disconnect the battery cables.
  12.  
  13. Remove the upper intake manifold sight shield as follows:
    1. Remove the retaining bolt in the front of the shield.
    2.  
    3. Lift up on the front of the shield, then left the shield off the rear bracket.
    4.  

  14.  
  15. Remove or disconnect the following:
    NOTE
    After you remove the duct, cover the turbocharger openings and ducts with tape to prevent foreign objects from entering.






    Air cleaner outlet duct from the air cleaner and turbocharger.
     
    Mass Air Flow (MAF) switch connector
     
    A/C pressure cycling switch connector
     
    Surge tank switch
     
    Engine wire harness clip from the accumulator
     
    Engine wire harness clips from the wheelhouse inner panel and engine bracket
     
    Air cleaner assembly and bracket
     
    Surge tank
     

  16.  
  17. Raise the vehicle.

    Front tires and wheels
     
    Both front fender wheelhouse inner panels
     

  18.  
  19. Lower the vehicle.

    Charged air cooler pipes and hoses from the engine and charged air cooler
     
    Radiator inlet hose form the radiator and engine
     
    Upper and lower fan shrouds
     
    Radiator outlet hose from the radiator
     
    Outlet heater hose from the outlet radiator hose
     
    Hose clips from the frame
     
    Radiator outlet hose from the engine
     
    Bolt securing the outlet heater hose pipe to the alternator mounting bracket
     
    Nut securing the outlet heater hose pipe to the fuel filter mounting bracket
     
    Secure the heater hose aside
     
    Upper radiator support
     
    Radiator
     
    Charged air cooler
     
    A/C condenser
     
    Alternator harness connector
     
    A/C refrigerant switch connector
     
    Dual alternator harness connector, if equipped
     
    A/C compressor clutch connector
     
    Harness clip from the A/C compressor bracket
     
    Battery cable from the alternator and auxiliary alternator, if equipped
     
    Battery cable harness clips from the bracket
     
    Bolt securing the battery cable junction block from the power steering pump
     
    Move and secure the battery cables aside
     
    Both fuel injection control module harness connectors, by flipping the latch up
     
    Engine wire harness from the retainer
     
    Fuel lines at the engine
     
    Remove the nut and the fuel line bracket from the upper valve rocker arm cover stud
     
    Fuel lines aside
     
    Power supply cable from the glow plug relay
     
    Drive belt
     
    Suction hose form the accumulator. You can leave the compressor end on the compressor
     
    A/C compressor bolts, then move the compressor, with the hoses attached, to the right side of the engine compartment
     
    Wiring harness to the left side of the engine and tie aside
     
    Bolts holding the power steering pump front bracket to the pump and A/C compressor mounting bracket
     
    A/C compressor and power steering pump bracket. Once the battery cables are removed from the engine, the power steering pump can be removed further out of the way
     
    Positive Crankcase Ventilation (PCV) oil separator from the bracket
     
    Bolts securing the PCV separator bracket and fuel bleed valve
     
    Right idler pulley (ribbed)
     
    Alerantor mounting bracket and secure aside. You do not have to remove the alternator or the belt tensioner
     
    Inlet heater hose from the heater core inlet, using Quick Connect-Disconnect tool No. J 43181
     
    Bolt and ground wires from the rear of the left cylinder head
     

  20.  
  21. Raise the vehicle

    Oil pan skid plate
     
    Engine protection shield, if equipped
     
    Bolt for the negative battery cable and engine wiring harness ground wire from the left side of the engine
     
    Bolts holding the battery cable channel retainer to the lower crankcase
     
    Engine coolant heater cord
     
    Starter motor
     
    Nut securing the battery cable bracket to the right side of the lower crankcase
     
    Bolt holding the auxiliary negative battery cable and the engine wiring harness ground wires to the right side of the engine
     
    Position the battery cables aside
     
    Exhaust pipe-to-exhaust outlet clamp
     
    Lower oil pan, if 4WD
     

  22.  
  23. If equipped with an automatic transmission, matchmark the installed position of the flywheel and torque converter.

    Torque converter bolts through the starter opening
     
    Transmission oil line clip nut if equipped with A/T
     
    Nuts securing the transmission fluid fill tube bracket, if equipped with A/T
     
    Transmission-to-engine stud and bolts. Note the location of the studs and any brackets attached to the studs
     

  24.  
  25. Lower the vehicle to work through the wheel opening

    Engine mount-to-frame bracket bolts
     

  26.  
  27. Lower the vehicle.
  28.  
  29. Install Engine Lifting Bracket tool No. J 36857 to the rear of the left cylinder head with a suitable bolt.
  30.  
  31. Install Engine Lifting Bracket tool No. J 36857 to the front of the right cylinder head with a suitable bolt.
  32.  
  33. Install a suitable lifting device. The engine will have to be angled to remove it. Use a load positioning sling to help in angling the engine.
  34.  
  35. Raise the vehicle off the engine mounts.
  36.  
  37. Remove the left and right engine mount frame brackets.
  38.  
  39. Remove the engine assembly from the vehicle.
  40.  
  41. Secure the engine on an engine stand by removing the following components:

    Flywheel/flexplate
     
    Rear main seal
     
    Exhaust outlet
     
    Oil pan
     
    Flywheel housing
     

  42.  

To install:

  1. Install Engine Lifting Bracket tool No. J 36857 to the rear of the left cylinder head with a suitable bolt.

    Click image to see an enlarged view

    Fig. Install the engine lifting bracket to the rear of the left cylinder head

  2.  
  3. Install Engine Lifting Bracket tool No. J 36857 to the front of the right cylinder head with a suitable bolt.
  4.  
  5. Install a suitable lifting device. The engine will have to be angled to install it. Use a load positioning sling to help in angling the engine.
  6.  
  7. Install or connect the following:

    Engine in the vehicle
     
    2 transmission-to-engine bolts, loosely
     
    Left and right side engine mount frame brackets. Tighten to 55 ft. lbs. (75 Nm)
     
    Engine mount-to-frame bracket bolts and tighten to 50 ft. lbs. (65 Nm)
     

  8.  
  9. Remove the lifting brackets from the cylinder heads.

    Transmission-to-engine bolts/studs and tighten to 37 ft. lbs. (50 Nm)

    Click image to see an enlarged view

    Fig. Transmission-to-engine mounting-6.6L engine with A/T

     
    Torque converter bolts, if equipped with an A/T. Tighten to 44 ft. lbs. (60 Nm).
     

  10.  
  11. Install the remaining components in the reverse of the removal procedure, noting the following important specifications and steps:

    Transmission fluid tube bracket nuts: 13 ft. lbs. (18 Nm)
     
    Transmission oil cooler line clip bolt: 80 inch lbs. (9 Nm)
     
    Exhaust pipe clamp: 30 ft. lbs. (40 Nm)
     
    Ground wire bolt: 25 ft. lbs. (34 Nm)
     
    Battery cable bracket bolts: 106 inch lbs. (12 Nm)
     
    Cable and ground wire bolts: 25 ft. lbs. (34 Nm)
     
    Oil pan skid plate bolts: 15 ft. lbs. (20 Nm)
     
    Engine protection shield bolts: 15 ft. lbs. (20 Nm)
     
    Alternator bracket bolt: 37 ft. lbs. (50 Nm)
     
    Idler pulley bolt: 32 ft. lbs. (43 Nm)
     
    A/C compressor bolts: 37 ft. lbs. (50 Nm).
     

  12.  
  13. Refill the crankcase and the cooling system.
  14.  
  15. Recharge the air conditioning system.
  16.  


CAUTION
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the engine cover.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Recover the HVAC refrigerant.
  8.  
  9. Drain the cooling system.
  10.  
  11. Remove the cooling fan and accessory drive belt.
  12.  
  13. Unplug the generator electrical connector. Unbolt and reposition the generator to access the output wire nut. Remove the generator.
  14.  
  15. Disconnect the RH engine wiring harness connector. Remove the 2 RH engine wiring harness bracket bolts and position aside. Remove the 2 wiring harness routing bolts.
  16.  
  17. Remove the transmission tube bolt and reposition the transmission tube. Remove the oil indicator tube bracket bolt.
  18.  
  19. Remove the drive belt tensioner bolt and tensioner.
  20.  
  21. Remove the bolts and the generator mounting bracket.
  22.  
  23. If equipped, remove the auxiliary generator. Remove the auxiliary generator bracket bolt and bracket.
  24.  
  25. If equipped with a dual generator system, remove the bolt from the left side idler pulley and remove the idler pulley.
  26.  
  27. Unplug the A/C compressor clutch electrical connector and the A/C cut out switch electrical connector.
  28.  
  29. Disconnect the A/C suction and discharge lines at the compressor. Remove the A/C compressor.
  30.  
  31. Remove the power steering pump and bracket bolts. Position the power steering pump aside and secure.
  32.  
  33. Remove the A/C and power steering bracket mounting nuts/bolts and bracket.
  34.  
  35. Remove the fuel line bolt and position the fuel line aside.
  36.  
  37. Compress the clamp and disconnect the turbocharger inlet cooling hose/pipe.
  38.  
  39. Remove the oil fill tube bolts and the oil fill tube.
  40.  
  41. Remove the Exhaust Gas Recirculation (EGR) valve coolant pipe to thermostat housing bolt.
  42.  
  43. Unplug the coolant temperature sensor electrical connector.
  44.  
  45. Remove the fuel pipe bracket bolt.
  46.  
  47. Remove the thermostat housing crossover bolts/nuts and the thermostat housing crossover. Remove the thermostat pipe.
  48.  
  49. Unplug the intake air heater electrical connector.
  50.  
  51. Disconnect the engine harness electrical connector from the Manifold Absolute Pressure (MAP) sensor.
  52.  
  53. Disconnect the positive cable from the IAH.
  54.  
  55. Remove the intake manifold tube with the stud.
  56.  
  57. Remove and discard the 2 metal EGR gaskets from the EGR valve.
  58.  
  59. Remove and discard the O-ring seal from the center intake manifold.
  60.  
  61. Remove the air intake pipe.
  62.  
  63. Remove the right and left exhaust pipes.
  64.  
  65. Remove the EGR coolant hose.
  66.  
  67. Compress the clamp and disconnect the EGR heater inlet hose/pipe from the EGR cooler tube. Remove the EGR cooler tube bracket bolts.
  68.  
  69. Remove the crankcase ventilation hose/pipe.
  70.  
  71. Unplug the EGR solenoid electrical connector. Remove the EGR valve and EGR cooler tube as an assembly. Remove the 2 bolts and the EGR cooler tube bracket.
  72.  
  73. Unplug the engine wiring harness electrical connector from the turbocharger vane position sensor and solenoid valve.
  74.  
  75. Remove the turbocharger upper heat shield.
  76.  
  77. Reposition the turbocharger coolant outlet pipe clamp and remove the hose from the turbocharger pipe. Disconnect the fuel feed and return pipes.
  78.  
  79. Disconnect the positive battery cable from the glow plug control module. Remove the glow plug control module.
  80.  
  81. Remove the glow plug control module bracket bolts. Remove the fuel line bracket bolt.
  82.  
  83. Remove the turbocharger coolant inlet pipe bolt and remove the hose from the turbocharger.
  84.  
  85. Remove the turbocharger oil feed pipe banjo bolt and washer. Discard the banjo bolt and washer. Reposition and secure the turbocharger oil fed pipe out of the way.
  86.  
  87. Remove the turbocharger oil return pipe nuts at the top of the flywheel housing.
  88.  
  89. Remove the turbocharger (with the oil return pipe).
  90.  
  91. Remove and discard the turbocharger oil return pipe gasket at the flywheel housing. Remove the turbocharger lower heat shield, oil feed pipe, washer, and pipe.
  92.  
  93. Unplug the LH main engine wiring harness connector and remove the bracket bolts.
  94.  
  95. Remove the LH glow plug nuts and the routing bolts.
  96.  
  97. Unplug the fuel injector electrical connectors, the Intake Air Temperature (IAT) sensor and fuel rail temperature sensor electrical connectors.
  98.  
  99. Unplug the Engine Coolant Temperature (ECT) wiring harness electrical connector and the oil pressure sensor electrical wiring harness electrical connector. Position the engine wiring harness over the RH side of engine.
  100.  
  101. Remove the fuel feed/return pipe bracket bolt. Disconnect the fuel hoses from the fuel pipe.
  102.  
  103. Remove the fuel line bracket bolt. Disconnect the fuel pump hose from the fuel pipe.
  104.  
  105. Disconnect the fuel injector return hoses from the return pipe assembly. Remove the fuel pipe. Remove the fuel pipe clamp bolt and turbocharger coolant inlet pipe bracket bolt.
  106.  
  107. Remove the center intake manifold.
  108.  
  109. Remove the fuel pump to LH fuel rail pipe. Compress the clamp and remove the fuel pressure relief hose. Remove the fuel pipe bracket bolt, disconnect the hose at the fuel pump and remove the fuel pipe/hose assembly.
  110.  
  111. Remove the LH to RH fuel rail pipe. Remove the LH fuel injector feed pipes. Remove the 2 bolts and the LH fuel rail.
  112.  
  113. Unplug the Fuel Rail Pressure (FRP) sensor electrical connector. Remove the RH fuel injector feed pipes. Remove the 2 bolts and the RH fuel rail.
  114.  
  115. Remove the 2 bolts and the turbocharger cooling outlet pipe.
  116.  
  117. Remove the intake manifolds.
  118.  
  119. Unplug the fuel pump electrical connector. Remove the 4 bolts and fuel injection pump.
  120.  
  121. Remove the transmission fill tube. Remove the engine oil indicator tube.
  122.  
  123. Remove the transmission.
  124.  
  125. Remove the engine flywheel.
  126.  
  127. Remove the upper oil pan.
  128.  
  129. Remove the engine flywheel housing.
  130.  
  131. Remove the oil pump pickup tube. Remove the oil filter adapter and the oil cooler assembly.
  132.  
  133. Remove the exhaust manifolds.
  134.  
  135. Disconnect any remaining ground straps from the engine.
  136.  
  137. Using tool J 36857 or similar engine lift hooks, install a suitable lifting device.
    NOTE
    The engine will have to be angled in order to remove. Use a load positioning sling to assist in angling the engine.

  138.  
  139. Raise the engine off the engine mounts.
  140.  
  141. Remove the left engine mount to engine mount frame bracket bolts. Remove the left engine mount to engine bolts. Remove the left engine mount bracket to frame bolts.
  142.  
  143. Remove the right engine mount to engine mount frame bracket bolts. Remove the right engine mount to engine bolts. Remove the right engine mount bracket to frame bolts.

    Click image to see an enlarged view

    Fig. Engine mount to frame mounting bolts-6.6L engines



    Click image to see an enlarged view

    Fig. Engine mount to engine mounting bolts-6.6L engines

  144.  
  145. Remove the engine from the vehicle.
  146.  

To install:

  1. Installation is the reverse of removal. Note the following and observe the following torque specifications:

    Engine mount bracket to frame bolts to 48 ft. lbs. (65 Nm)
     
    Engine mount to engine bolts to 43 ft. lbs. (58 Nm)
     
    Engine mount to engine mount bracket bolts to 48 ft. lbs. (65 Nm)
     

  2.  
  3. Fill the engine to the proper level with oil and coolant. Prime the fuel system.
  4.  
  5. Check for and correct any leaks. Recharge the A/C system if equipped.
  6.  


NOTE
In order to remove the engine, the vehicle must be on a lift. the front tires also need to be removed. You will have to support the vehicle by its frame for tire removal.

  1. Drain the cooling system.
  2.  
  3. Discharge and recover the air conditioning system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Raise the hood to the servicing position. Move the hood hinge bolt to hold the hood in the servicing position.
  8.  
  9. Disconnect the battery cables.
  10.  
  11. Remove the upper intake manifold sight shield as follows:
    1. Remove the retaining bolt in the front of the shield.
    2.  
    3. Lift up on the front of the shield, then left the shield off the rear bracket.
    4.  

  12.  
  13. Remove or disconnect the following:
    NOTE
    After you remove the duct, cover the turbocharger openings and ducts with tape to prevent foreign objects from entering.






    Air cleaner outlet duct from the air cleaner and turbocharger.
     
    Mass Air Flow (MAF) switch connector
     
    A/C pressure cycling switch connector
     
    Surge tank switch
     
    Engine wire harness clip from the accumulator
     
    Engine wire harness clips from the wheelhouse inner panel and engine bracket
     
    Air cleaner assembly and bracket
     
    Surge tank
     

  14.  
  15. Raise the vehicle.

    Front tires and wheels
     
    Both front fender wheelhouse inner panels
     

  16.  
  17. Lower the vehicle.

    Charged air cooler pipes and hoses from the engine and charged air cooler
     
    Radiator inlet hose form the radiator and engine
     
    Upper and lower fan shrouds
     
    Radiator outlet hose from the radiator
     
    Outlet heater hose from the outlet radiator hose
     
    Hose clips from the frame
     
    Radiator outlet hose from the engine
     
    Bolt securing the outlet heater hose pipe to the alternator mounting bracket
     
    Nut securing the outlet heater hose pipe to the fuel filter mounting bracket
     
    Secure the heater hose aside
     
    Upper radiator support
     
    Radiator
     
    Charged air cooler
     
    A/C condenser
     
    Alternator harness connector
     
    A/C refrigerant switch connector
     
    Dual alternator harness connector, if equipped
     
    A/C compressor clutch connector
     
    Harness clip from the A/C compressor bracket
     
    Battery cable from the alternator and auxiliary alternator, if equipped
     
    Battery cable harness clips from the bracket
     
    Bolt securing the battery cable junction block from the power steering pump
     
    Move and secure the battery cables aside
     
    Both fuel injection control module harness connectors, by flipping the latch up
     
    Engine wire harness from the retainer
     
    Fuel lines at the engine
     
    Remove the nut and the fuel line bracket from the upper valve rocker arm cover stud
     
    Fuel lines aside
     
    Power supply cable from the glow plug relay
     
    Drive belt
     
    Suction hose from the accumulator. You can leave the compressor end on the compressor.
     
    A/C compressor bolts, then move the compressor, with the hoses attached, to the right side of the engine compartment
     
    Wiring harness to the left side of the engine and tie aside
     
    Bolts holding the power steering pump front bracket to the pump and A/C compressor mounting bracket
     
    A/C compressor and power steering pump bracket. Once the battery cables are removed from the engine, the power steering pump can be removed further out of the way
     
    Positive Crankcase Ventilation (PCV) oil separator from the bracket
     
    Bolts securing the PCV separator bracket and fuel bleed valve
     
    Right idler pulley (ribbed)
     
    Alternator mounting bracket and secure aside. You do not have to remove the alternator or the belt tensioner
     
    Inlet heater hose from the heater core inlet, using Quick Connect-Disconnect tool No. J 43181
     
    Bolt and ground wires from the rear of the left cylinder head
     

  18.  
  19. Raise the vehicle

    Oil pan skid plate
     
    Engine protection shield, if equipped
     
    Bolt for the negative battery cable and engine wiring harness ground wire from the left side of the engine
     
    Bolts holding the battery cable channel retainer to the lower crankcase
     
    Engine coolant heater cord
     
    Starter motor
     
    Nut securing the battery cable bracket to the right side of the lower crankcase
     
    Bolt holding the auxiliary negative battery cable and the engine wiring harness ground wires to the right side of the engine
     
    Position the battery cables aside
     
    Exhaust pipe-to-exhaust outlet clamp
     
    Lower oil pan, if 4WD
     

  20.  
  21. If equipped with an automatic transmission, matchmark the installed position of the flywheel and torque converter.

    Torque converter bolts through the starter opening
     
    Transmission oil line clip nut if equipped with A/T
     
    Nuts securing the transmission fluid fill tube bracket, if equipped with A/T
     
    Transmission-to-engine stud and bolts. Note the location of the studs and any brackets attached to the studs
     

  22.  
  23. Lower the vehicle to work through the wheel opening

    Engine mount-to-frame bracket bolts
     

  24.  
  25. Lower the vehicle.
  26.  
  27. Install Engine Lifting Bracket tool No. J 36857 to the rear of the left cylinder head with a suitable bolt.
  28.  
  29. Install Engine Lifting Bracket tool No. J 36857 to the front of the right cylinder head with a suitable bolt.
  30.  
  31. Install a suitable lifting device. The engine will have to be angled to remove it. Use a load positioning sling to help in angling the engine.
  32.  
  33. Raise the vehicle off the engine mounts.
  34.  
  35. Remove the left and right engine mount frame brackets.
  36.  
  37. Remove the engine assembly from the vehicle.
  38.  
  39. Secure the engine on an engine stand by removing the following components:

    Flywheel/flexplate
     
    Rear main seal
     
    Exhaust outlet
     
    Oil pan
     
    Flywheel housing
     

  40.  

To install:

  1. Install Engine Lifting Bracket tool No. J 36857 to the rear of the left cylinder head with a suitable bolt.

    Click image to see an enlarged view

    Fig. Install the engine lifting bracket to the rear of the left cylinder head-6.6L engines

  2.  
  3. Install Engine Lifting Bracket tool No. J 36857 to the front of the right cylinder head with a suitable bolt.
  4.  
  5. Install a suitable lifting device. The engine will have to be angled to install it. Use a load positioning sling to help in angling the engine.
  6.  
  7. Install or connect the following:

    Engine in the vehicle
     
    2 transmission-to-engine bolts, loosely
     
    Left and right side engine mount frame brackets and tighten to 55 ft. lbs. (75 Nm)
     
    Engine mount-to-frame bracket bolts and tighten to 50 ft. lbs. (65 Nm)
     

  8.  
  9. Remove the lifting brackets from the cylinder heads.

    Transmission-to-engine bolts/studs and tighten to 37 ft. lbs. (50 Nm)

    Click image to see an enlarged view

    Fig. Transmission-to-engine mounting-6.6L engines with A/T

     
    Torque converter bolts and tighten to 44 ft. lbs. (60 Nm)
     

  10.  
  11. Install the remaining components in the reverse of the removal procedure, noting the following important specifications and steps:

    Transmission fluid tube bracket nuts: 13 ft. lbs. (18 Nm)
     
    Transmission oil cooler line clip bolt: 80 inch lbs. (9 Nm)
     
    Exhaust pipe clamp: 30 ft. lbs. (40 Nm)
     
    Ground wire bolt: 25 ft. lbs. (34 Nm)
     
    Battery cable bracket bolts: 106 inch lbs. (12 Nm)
     
    Cable and ground wire bolts: 25 ft. lbs. (34 Nm)
     
    Oil pan skid plate bolts: 15 ft. lbs. (20 Nm)
     
    Engine protection shield bolts: 15 ft. lbs. (20 Nm)
     
    Alternator bracket bolt: 37 ft. lbs. (50 Nm)
     
    Idler pulley bolt: 32 ft. lbs. (43 Nm)
     
    A/C compressor bolts: 37 ft. lbs. (50 Nm)
     

  12.  
  13. Refill the crankcase and the cooling system.
  14.  
  15. Recharge the air conditioning system.
  16.  

7.4L Engine
  1. Drain the cooling system.
  2.  
  3. Remove or disconnect the following:

    Hood
     
    Negative battery cable
     
    Air cleaner
     
    Radiator and fan shroud
     
    Engine wiring
     
    Accelerator, cruise control linkage
     
    Fuel supply lines
     
    Vacuum wires
     
    Air conditioning compressor, if used, and lay aside
     
    Power steering pump and position it out of the way. It's not necessary to disconnect the fluid lines.
     
    Exhaust pipes from the manifold
     
    Starter
     
    Torque converter cover
     
    Converter-to-flexplate bolts
     

  4.  
  5. Support the transmission

    Engine-to-engine bolts
     
    Rear engine mounting-to-frame bolts and the front through bolts
     
    Engine
     

  6.  

To install:

  1. Lower the engine into the vehicle.
  2.  
  3. Install or connect the following:

    Engine mounting bolts. Torque the rear engine mounting-to-frame bolts or nuts to 45 ft. lbs. (54 Nm), the front through bolts to 70 ft. lbs. (97 Nm) and the front nuts to 50 ft. lbs. (67 Nm).
     
    Engine-to-engine bolts. Torque the bolts to 35 ft. lbs. (47 Nm).
     

  4.  
  5. Remove transmission support.

    Converter-to-flexplate bolts and torque them to 35 ft. lbs. (47 Nm)
     
    Fuel gauge wiring
     
    Starter
     
    Torque converter cover
     
    Exhaust pipes at the manifold
     
    Power steering pump
     
    Air conditioning compressor
     
    Vacuum hoses
     
    Fuel supply line
     
    Accelerator, cruise control linkage
     
    Engine wiring
     
    Radiator and fan shroud
     
    Air cleaner
     
    Hood
     
    Negative battery cable
     

  6.  
  7. Refill the coolant.
  8.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Hood
     
    Negative battery cable
     
    Air cleaner
     
    Radiator and fan shroud
     
    Engine wiring
     
    Accelerator, cruise control linkage
     
    Fuel supply lines
     
    Vacuum wires
     
    Air conditioning compressor, if used, and lay aside
     
    Power steering pump and position it out of the way. It's not necessary to disconnect the fluid lines.
     
    Exhaust pipes from the manifold
     
    Starter
     
    Torque converter cover
     
    Converter-to-flexplate bolts
     

  6.  
  7. Support the transmission

    Bellhousing-to-engine bolts
     
    Rear engine mounting-to-frame bolts and the front through bolts
     
    Engine
     

  8.  

To install:

  1. Lower the engine.
  2.  
  3. Install or connect the following:

    Engine mounting bolts. Torque the rear engine mounting-to-frame bolts or nuts to 45 ft. lbs. (54 Nm), the front through bolts to 70 ft. lbs. (97 Nm) and the front nuts to 50 ft. lbs. (67 Nm)
     
    Bellhousing-to-engine bolts. Torque the bolts to 35 ft. lbs. (47 Nm)
     

  4.  
  5. Remove transmission support.

    Converter-to-flexplate bolts and torque them to 35 ft. lbs. (47 Nm)
     
    Fuel gauge wiring
     
    Starter
     
    Torque converter cover
     
    Exhaust pipes at the manifold
     
    Power steering pump
     
    Air conditioning compressor
     
    Vacuum hoses
     
    Fuel supply line
     
    Accelerator, cruise control linkage
     
    Engine wiring
     
    Radiator and fan shroud
     
    Air cleaner
     
    Hood
     
    Negative battery cable
     

  6.  
  7. Refill the coolant.
  8.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Hood
     
    Negative battery cable
     
    Air cleaner
     
    Radiator and fan shroud
     
    Engine wiring
     
    Accelerator, cruise control linkage
     
    Fuel supply lines
     
    Vacuum wires
     
    Air conditioning compressor, if used, and lay aside
     
    Power steering pump and position it out of the way. It's not necessary to disconnect the fluid lines.
     
    Exhaust pipes from the manifold
     
    Starter
     
    Torque converter cover
     
    Tonverter-to-flexplate bolts
     

  6.  
  7. Support the transmission

    Bellhousing-to-engine bolts
     
    Rear engine mounting-to-frame bolts and the front through bolts
     
    Engine
     

  8.  

To install:

  1. Lower the engine.
  2.  
  3. Install or connect the following:

    Engine mounting bolts. Torque the rear engine mounting-to-frame bolts or nuts to 45 ft. lbs. (54 Nm), the front through bolts to 70 ft. lbs. (97 Nm) and the front nuts to 50 ft. lbs. (67 Nm)
     
    Bellhousing-to-engine bolts. Torque the bolts to 35 ft. lbs. (47 Nm)
     

  4.  
  5. Remove transmission support.

    Converter-to-flexplate bolts and torque them to 35 ft. lbs. (47 Nm)
     
    Fuel gauge wiring
     
    Starter
     
    Torque converter cover
     
    Exhaust pipes at the manifold
     
    Power steering pump
     
    Air conditioning compressor
     
    Vacuum hoses
     
    Fuel supply line
     
    Accelerator, cruise control linkage
     
    Engine wiring
     
    Radiator and fan shroud
     
    Air cleaner
     
    Hood
     
    Negative battery cable
     

  6.  
  7. Refill the coolant.
  8.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Hood
     
    Negative battery cable
     
    Air cleaner
     
    Radiator and fan shroud
     
    Engine wiring
     
    Accelerator, cruise control linkage
     
    Fuel supply lines
     
    Vacuum wires
     
    Air conditioning compressor, if used, and lay aside
     
    Power steering pump and position it out of the way. It's not necessary to disconnect the fluid lines.
     
    Exhaust pipes from the manifold
     
    Starter
     
    Torque converter cover
     
    Tonverter-to-flexplate bolts
     

  6.  
  7. Support the transmission

    Bellhousing-to-engine bolts
     
    Rear engine mounting-to-frame bolts and the front through bolts
     
    Engine
     

  8.  

To install:

  1. Lower the engine.
  2.  
  3. Install or connect the following:

    Engine mounting bolts. Torque the rear engine mounting-to-frame bolts or nuts to 45 ft. lbs. (54 Nm), the front through bolts to 70 ft. lbs. (97 Nm) and the front nuts to 50 ft. lbs. (67 Nm)
     
    Bellhousing-to-engine bolts. Torque the bolts to 35 ft. lbs. (47 Nm)
     

  4.  
  5. Remove transmission support.

    Converter-to-flexplate bolts and torque them to 35 ft. lbs. (47 Nm)
     
    Fuel gauge wiring
     
    Starter
     
    Torque converter cover
     
    Exhaust pipes at the manifold
     
    Power steering pump
     
    Air conditioning compressor
     
    Vacuum hoses
     
    Fuel supply line
     
    Accelerator, cruise control linkage
     
    Engine wiring
     
    Radiator and fan shroud
     
    Air cleaner
     
    Hood
     
    Negative battery cable
     

  6.  
  7. Refill the coolant.
  8.  

8.1L Engine
  1. Raise the hood to the servicing position. Move the hood hinge bolt to hold the hood in the servicing position.
  2.  
  3. Release the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative, then positive battery cables
     
    Coolant
     
    A/C refrigerant
     
    Engine oil cooler lines from the engine block
     
    Transmission-to-engine bolts
     
    Clutch pressure plate bolts, if equipped
     
    Torque converter bolts, if equipped
     
    Catalytic converter
     
    Exhaust manifold pipe
     
    Hoses from power steering pump, then plug the lines and ports
     
    Starter motor
     




  6.  
  7. Raise the vehicle.

    Engine electrical harness and tie aside
     
    Alternator
     
    Ground cable bolt from engine block
     
    Exhaust Gas Recirculation (EGR) valve adapter
     
    Vacuum lines (tag before removal)
     
    Throttle Actuator Control (TAC) module electrical connector
     

  8.  
  9. Install Engine Lift Brackets part No. J 36857, or equivalent, to the rear of the right cylinder head and the front of the left cylinder head.

    Click image to see an enlarged view

    Fig. Install suitable lift brackets to the rear of the right head and the front of the left head

  10.  
  11. Install the attaching bolt and washer. Use part No. 9428217 with 1560963. Tighten the bolts to 30 ft. lbs. (40 Nm).
  12.  
  13. Remove or disconnect the following:

    Engine mount heat shield bolt and shields
     
    Engine mount-to-engine mount bracket bolts
     
    Engine from the vehicle, using a suitable lifting device. Place on a suitable stand.
     
    A/C compressor/power steering pump bracket from the cylinder head
     
    Lift brackets from the cylinder head
     

  14.  

To install:

  1. Install Engine Lift Brackets part No. J 36857, or equivalent, to the rear of the right cylinder head and the front of the left cylinder head.
  2.  
  3. Install the attaching bolt and washer. Use part No. 9428217 with 1560963. Tighten the bolts to 30 ft. lbs. (40 Nm).
  4.  
  5. Install or connect the following:

    A/C compressor/power steering mounting bracket. Tighten the bolts and nut to 37 ft. lbs. (50 Nm).
     
    Alternator bracket
     
    Engine into the vehicle
     
    Engine mount-to-engine mount bracket bolts
     
    Engine mount heat shield and bolts
     

  6.  
  7. Remove the lift hooks from the cylinder heads, then raise the vehicle.

    Engine oil cooler lines
     
    Transmission-to-engine bolts
     
    Clutch pressure plate bolts, if equipped
     
    Torque converter bolts, if equipped
     
    Catalytic converter
     
    Exhaust manifold pipe
     
    Hoses to the power steering pump
     
    Starter motor
     

  8.  
  9. Lower the vehicle.

    Engine electrical harness. Make sure the harness is properly routed.
     
    Alternator
     
    Ground cable bolt to engine block and tighten to 12 ft. lbs. (16 Nm)
     
    EGR valve adapter
     
    Vacuum lines, as tagged during removal
     
    TAC module electrical connector
     
    Radiator
     
    A/C compressor
     
    Fuel feed and return lines
     
    Ignition coils
     
    Positive, then negative battery cables
     
    Air cleaner outlet duct and secure with the clamp
     

  10.  
  11. Lower the hood from the service position.
  12.  
  13. Properly recharge the A/C system.
  14.  
  15. Fill the engine with oil.
  16.  
  17. Fill the engine with coolant.
  18.  
  19. Perform the Crankshaft Position (CKP) sensor variation learn procedure:
    1. Install a suitable scan tool and check for Diagnostic Trouble Codes (DTCs). If any DTCs, other than P1336 are set, resolve those codes first, before proceeding with this procedure.
    2.  
    3. With the scan tool, select the crankshaft position variation learn procedure.
    4.  
    5. Observe the fuel cut-off for the 8.1L engine.
    6.  
    7. The scan tool will instruct you to perform certain steps, make sure you follow all directions given by the scan tool exactly.
    8.  
    9. Enable the crankshaft position system variation learn procedure.
      NOTE
      While the learn procedure is in progress, release the throttle immediately when the engine started to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete.

    10.  
    11. Slowly increase the engine speed to the RPM that you observed.
    12.  
    13. Immediately release the throttle when fuel cut-out is reached.
    14.  
    15. The scan tool displays: Learn Status: Learned this ignition. If the scan tool does NOT display this message and not other DTCs set, you must perform further troubleshooting.
    16.  
    17. Turn the ignition OFF for 30 seconds after the learn procedure has been completed successfully.
    18.  

  20.  
  21. Start and run the engine, then check for leaks.
  22.  

  1. Raise the hood to the servicing position. Move the hood hinge bolt to hold the hood in the servicing position.
  2.  
  3. Release the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative, then positive battery cables
     
    Coolant
     
    A/C refrigerant
     
    Engine oil cooler lines from the engine block
     
    Transmission-to-engine bolts
     
    Clutch pressure plate bolts, if equipped
     
    Torque converter bolts, if equipped
     
    Catalytic converter
     
    Exhaust manifold pipe
     
    Hoses from power steering pump, then plug the lines and ports
     
    Starter motor
     

  6.  
  7. Raise the vehicle.

    Engine electrical harness and tie aside
     
    Alternator
     
    Ground cable bolt from engine block
     
    Exhaust Gas Recirculation (EGR) valve adapter
     
    Vacuum lines (tag before removal)
     
    Throttle Actuator Control (TAC) module electrical connector
     

  8.  
  9. Install Engine Lift Brackets tool J36857, or equivalent, to the rear of the right cylinder head and the front of the left cylinder head.

    Click image to see an enlarged view

    Fig. Install suitable lift brackets to the rear of the right head and the front of the left head

  10.  
  11. Install the attaching bolt and washer. Use part No. 9428217 with 1560963. Tighten the bolts to 30 ft. lbs. (40 Nm).
  12.  
  13. Remove or disconnect the following:

    Engine mount heat shield bolt and shields
     
    Engine mount-to-engine mount bracket bolts
     
    Engine from the vehicle, using a suitable lifting device. Place on a suitable stand.
     
    A/C compressor/power steering pump bracket from the cylinder head
     
    Lift brackets from the cylinder head
     

  14.  

To install:

  1. Install Engine Lift Brackets tool J36857, or equivalent, to the rear of the right cylinder head and the front of the left cylinder head.
  2.  
  3. Install the attaching bolt and washer. Use part No. 9428217 with 1560963. Tighten the bolts to 30 ft. lbs. (40 Nm).
  4.  
  5. Install or connect the following:

    A/C compressor/power steering mounting bracket. Tighten the bolts and nut to 37 ft. lbs. (50 Nm)
     
    Alternator bracket
     
    Engine into the vehicle
     
    Engine mount-to-engine mount bracket bolts
     
    Engine mount heat shield and bolts
     

  6.  
  7. Remove the lift hooks from the cylinder heads, then raise the vehicle.

    Engine oil cooler lines
     
    Transmission-to-engine bolts
     
    Clutch pressure plate bolts, if equipped
     
    Torque converter bolts, if equipped
     
    Catalytic converter
     
    Exhaust manifold pipe
     
    Hoses to the power steering pump
     
    Starter motor
     

  8.  
  9. Lower the vehicle.

    Engine electrical harness. Make sure the harness is properly routed.
     
    Alternator
     
    Ground cable bolt to engine block. Tighten to 12 ft. lbs. (16 Nm).
     
    EGR valve adapter
     
    Vacuum lines, as tagged during removal
     
    TAC module electrical connector
     
    Radiator
     
    A/C compressor
     
    Fuel feed and return lines
     
    Ignition coils
     
    Positive, then negative battery cables
     
    Air cleaner outlet duct and secure with the clamp
     

  10.  
  11. Lower the hood from the service position.
  12.  
  13. Properly recharge the A/C system.
  14.  
  15. Fill the engine with oil.
  16.  
  17. Fill the engine with coolant.
  18.  
  19. Perform the Crankshaft Position (CKP) sensor variation learn procedure:
    1. Install a suitable scan tool and check for Diagnostic Trouble Codes (DTCs). If any DTCs, other than P1336 are set, resolve those codes first, before proceeding with this procedure.
    2.  
    3. With the scan tool, select the crankshaft position variation learn procedure.
    4.  
    5. Observe the fuel cut-off for the 8.1L engine.
    6.  
    7. The scan tool will instruct you to perform certain steps, make sure you follow all directions given by the scan tool exactly.
    8.  
    9. Enable the crankshaft position system variation learn procedure.
      NOTE
      While the learn procedure is in progress, release the throttle immediately when the engine started to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete.

    10.  
    11. Slowly increase the engine speed to the RPM that you observed.
    12.  
    13. Immediately release the throttle when fuel cut-out is reached.
    14.  
    15. The scan tool displays: Learn Status: Learned this ignition. If the scan tool does NOT display this message and not other DTCs set, you must perform further troubleshooting.
    16.  
    17. Turn the ignition OFF for 30 seconds after the learn procedure has been completed successfully.
    18.  

  20.  
  21. Start and run the engine, then check for leaks.
  22.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Raise the hood to the servicing position. Move the hood hinge bolt to hold the hood in the servicing position.
  4.  
  5. Release the fuel system pressure.
  6.  
  7. Remove or disconnect the following:
    NOTE
    If your vehicle is equipped with air conditioning, refer to Section 1 for information regarding the implications of servicing your A/C system yourself. Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.



    Negative, then positive battery cables
     
    Coolant
     
    A/C refrigerant
     



    Engine oil cooler lines from the engine block
     
    Transmission-to-engine bolts
     
    Clutch pressure plate bolts, if equipped
     
    Torque converter bolts, if equipped
     
    Catalytic converter
     
    Exhaust manifold pipe
     
    Hoses from power steering pump, then plug the lines and ports
     
    Starter motor
     




  8.  
  9. Raise the vehicle.

    Engine electrical harness and tie aside
     
    Alternator
     
    Ground cable bolt from engine block
     
    Exhaust Gas Recirculation (EGR) valve adapter
     
    Vacuum lines (tag before removal)
     
    Throttle Actuator Control (TAC) module electrical connector
     

  10.  
  11. Install Engine Lift Brackets part No. J 36857, or equivalent, to the rear of the right cylinder head and the front of the left cylinder head.

    Click image to see an enlarged view

    Fig. Install suitable lift brackets to the rear of the right head and the front of the left head

  12.  
  13. Install the attaching bolt and washer. Use part No. 9428217 with 1560963. Tighten the bolts to 30 ft. lbs. (40 Nm).
  14.  
  15. Remove or disconnect the following:

    Engine mount heat shield bolt and shields
     
    Engine mount-to-engine mount bracket bolts
     
    Engine from the vehicle, using a suitable lifting device. Place on a suitable stand
     
    A/C compressor/power steering pump bracket from the cylinder head.
     
    Lift brackets from the cylinder head.
     

  16.  

To install:

  1. Install Engine Lift Brackets part No. J 36857, or equivalent, to the rear of the right cylinder head and the front of the left cylinder head.
  2.  
  3. Install the attaching bolt and washer. Use part No. 9428217 with 1560963. Tighten the bolts to 30 ft. lbs. (40 Nm).
  4.  
  5. Install or connect the following:

    A/C compressor/power steering mounting bracket. Tighten the bolts and nut to 37 ft. lbs. (50 Nm)
     
    Alternator bracket
     
    Engine into the vehicle
     
    Engine mount-to-engine mount bracket bolts
     
    Engine mount heat shield and bolts
     

  6.  
  7. Remove the lift hooks from the cylinder heads, then raise the vehicle.

    Engine oil cooler lines
     
    Transmission-to-engine bolts
     
    Clutch pressure plate bolts, if equipped
     
    Torque converter bolts, if equipped
     
    Catalytic converter
     
    Exhaust manifold pipe
     
    Hoses to the power steering pump
     
    Starter motor
     

  8.  
  9. Lower the vehicle.

    Engine electrical harness. Make sure the harness is properly routed
     
    Alternator
     
    Ground cable bolt to engine block. Tighten to 12 ft. lbs. (16 Nm)
     
    EGR valve adapter
     
    Vacuum lines, as tagged during removal
     
    TAC module electrical connector
     
    Radiator
     
    A/C compressor
     
    Fuel feed and return lines
     
    Ignition coils
     
    Positive, then negative battery cables
     
    Air cleaner outlet duct and secure with the clamp
     

  10.  
  11. Lower the hood from the service position.
  12.  
  13. Properly recharge the A/C system.
  14.  
  15. Fill the engine with oil.
  16.  
  17. Fill the engine with coolant.
  18.  
  19. Perform the Crankshaft Position (CKP) sensor variation learn procedure:
    1. Install a suitable scan tool and check for Diagnostic Trouble Codes (DTCs). If any DTCs, other than P1336 are set, resolve those codes first, before proceeding with this procedure.
    2.  
    3. With the scan tool, select the crankshaft position variation learn procedure.
    4.  
    5. Observe the fuel cut-off for the 8.1L engine.
    6.  
    7. The scan tool will instruct you to perform certain steps, make sure you follow all directions given by the scan tool exactly.
    8.  
    9. Enable the crankshaft position system variation learn procedure.
      NOTE
      While the learn procedure is in progress, release the throttle immediately when the engine started to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete.

    10.  
    11. Sloiwly increase the engine speed to the RPM that you observed.
    12.  
    13. Immediately release the throttle when fuel cut-out is reached.
    14.  
    15. The scan tool displays: Learn Status: Learned this ignition. If the scan tool does NOT display this message and not other DTCs set, you must perform further troubleshooting.
    16.  
    17. Turn the ignition OFF for 30 seconds after the learn procedure has been completed successfully.
    18.  

  20.  
  21. Start and run the engine, then check for leaks.
  22.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Raise the hood to the servicing position. Move the hood hinge bolt to hold the hood in the servicing position.
  4.  
  5. Release the fuel system pressure.
  6.  
  7. Remove or disconnect the following:
    NOTE
    If your vehicle is equipped with air conditioning, refer to Section 1 for information regarding the implications of servicing your A/C system yourself. Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.



    Negative, then positive battery cables
     
    Coolant
     
    A/C refrigerant
     



    Engine oil cooler lines from the engine block
     
    Transmission-to-engine bolts
     
    Clutch pressure plate bolts, if equipped
     
    Torque converter bolts, if equipped
     
    Catalytic converter
     
    Exhaust manifold pipe
     
    Hoses from power steering pump, then plug the lines and ports
     
    Starter motor
     




  8.  
  9. Raise the vehicle.

    Engine electrical harness and tie aside
     
    Alternator
     
    Ground cable bolt from engine block
     
    Exhaust Gas Recirculation (EGR) valve adapter
     
    Vacuum lines (tag before removal)
     
    Throttle Actuator Control (TAC) module electrical connector
     

  10.  
  11. Install Engine Lift Brackets part No. J 36857, or equivalent, to the rear of the right cylinder head and the front of the left cylinder head.

    Click image to see an enlarged view

    Fig. Install suitable lift brackets to the rear of the right head and the front of the left head

  12.  
  13. Install the attaching bolt and washer. Use part No. 9428217 with 1560963. Tighten the bolts to 30 ft. lbs. (40 Nm).
  14.  
  15. Remove or disconnect the following:

    Engine mount heat shield bolt and shields
     
    Engine mount-to-engine mount bracket bolts
     
    Engine from the vehicle, using a suitable lifting device. Place on a suitable stand
     
    A/C compressor/power steering pump bracket from the cylinder head.
     
    Lift brackets from the cylinder head.
     

  16.  

To install:

  1. Install Engine Lift Brackets part No. J 36857, or equivalent, to the rear of the right cylinder head and the front of the left cylinder head.
  2.  
  3. Install the attaching bolt and washer. Use part No. 9428217 with 1560963. Tighten the bolts to 30 ft. lbs. (40 Nm).
  4.  
  5. Install or connect the following:

    A/C compressor/power steering mounting bracket. Tighten the bolts and nut to 37 ft. lbs. (50 Nm)
     
    Alternator bracket
     
    Engine into the vehicle
     
    Engine mount-to-engine mount bracket bolts
     
    Engine mount heat shield and bolts
     

  6.  
  7. Remove the lift hooks from the cylinder heads, then raise the vehicle.

    Engine oil cooler lines
     
    Transmission-to-engine bolts
     
    Clutch pressure plate bolts, if equipped
     
    Torque converter bolts, if equipped
     
    Catalytic converter
     
    Exhaust manifold pipe
     
    Hoses to the power steering pump
     
    Starter motor
     

  8.  
  9. Lower the vehicle.

    Engine electrical harness. Make sure the harness is properly routed
     
    Alternator
     
    Ground cable bolt to engine block. Tighten to 12 ft. lbs. (16 Nm)
     
    EGR valve adapter
     
    Vacuum lines, as tagged during removal
     
    TAC module electrical connector
     
    Radiator
     
    A/C compressor
     
    Fuel feed and return lines
     
    Ignition coils
     
    Positive, then negative battery cables
     
    Air cleaner outlet duct and secure with the clamp
     

  10.  
  11. Lower the hood from the service position.
  12.  
  13. Properly recharge the A/C system.
  14.  
  15. Fill the engine with oil.
  16.  
  17. Fill the engine with coolant.
  18.  
  19. Perform the Crankshaft Position (CKP) sensor variation learn procedure:
    1. Install a suitable scan tool and check for Diagnostic Trouble Codes (DTCs). If any DTCs, other than P1336 are set, resolve those codes first, before proceeding with this procedure.
    2.  
    3. With the scan tool, select the crankshaft position variation learn procedure.
    4.  
    5. Observe the fuel cut-off for the 8.1L engine.
    6.  
    7. The scan tool will instruct you to perform certain steps, make sure you follow all directions given by the scan tool exactly.
    8.  
    9. Enable the crankshaft position system variation learn procedure.
      NOTE
      While the learn procedure is in progress, release the throttle immediately when the engine started to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete.

    10.  
    11. Sloiwly increase the engine speed to the RPM that you observed.
    12.  
    13. Immediately release the throttle when fuel cut-out is reached.
    14.  
    15. The scan tool displays: Learn Status: Learned this ignition. If the scan tool does NOT display this message and not other DTCs set, you must perform further troubleshooting.
    16.  
    17. Turn the ignition OFF for 30 seconds after the learn procedure has been completed successfully.
    18.  

  20.  
  21. Start and run the engine, then check for leaks.
  22.  

  1. Raise the hood to the servicing position. Move the hood hinge bolt to hold the hood in the servicing position.
  2.  
  3. Release the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative, then positive battery cables
     
    Coolant
     
    A/C refrigerant
     
    Engine oil cooler lines from the engine block
     
    Transmission-to-engine bolts
     
    Clutch pressure plate bolts, if equipped
     
    Torque converter bolts, if equipped
     
    Catalytic converter
     
    Exhaust manifold pipe
     
    Hoses from power steering pump, then plug the lines and ports
     
    Starter motor
     




  6.  
  7. Raise the vehicle.

    Engine electrical harness and tie aside
     
    Alternator
     
    Ground cable bolt from engine block
     
    Exhaust Gas Recirculation (EGR) valve adapter
     
    Vacuum lines (tag before removal)
     
    Throttle Actuator Control (TAC) module electrical connector
     

  8.  
  9. Install Engine Lift Brackets part No. J 36857, or equivalent, to the rear of the right cylinder head and the front of the left cylinder head.

    Click image to see an enlarged view

    Fig. Install suitable lift brackets to the rear of the right head and the front of the left head

  10.  
  11. Install the attaching bolt and washer. Use part No. 9428217 with 1560963. Tighten the bolts to 30 ft. lbs. (40 Nm).
  12.  
  13. Remove or disconnect the following:

    Engine mount heat shield bolt and shields
     
    Engine mount-to-engine mount bracket bolts
     
    Engine from the vehicle, using a suitable lifting device. Place on a suitable stand.
     
    A/C compressor/power steering pump bracket from the cylinder head
     
    Lift brackets from the cylinder head
     

  14.  

To install:

  1. Install Engine Lift Brackets part No. J 36857, or equivalent, to the rear of the right cylinder head and the front of the left cylinder head.
  2.  
  3. Install the attaching bolt and washer. Use part No. 9428217 with 1560963. Tighten the bolts to 30 ft. lbs. (40 Nm).
  4.  
  5. Install or connect the following:

    A/C compressor/power steering mounting bracket. Tighten the bolts and nut to 37 ft. lbs. (50 Nm).
     
    Alternator bracket
     
    Engine into the vehicle
     
    Engine mount-to-engine mount bracket bolts
     
    Engine mount heat shield and bolts
     

  6.  
  7. Remove the lift hooks from the cylinder heads, then raise the vehicle.

    Engine oil cooler lines
     
    Transmission-to-engine bolts
     
    Clutch pressure plate bolts, if equipped
     
    Torque converter bolts, if equipped
     
    Catalytic converter
     
    Exhaust manifold pipe
     
    Hoses to the power steering pump
     
    Starter motor
     

  8.  
  9. Lower the vehicle.

    Engine electrical harness. Make sure the harness is properly routed.
     
    Alternator
     
    Ground cable bolt to engine block and tighten to 12 ft. lbs. (16 Nm)
     
    EGR valve adapter
     
    Vacuum lines, as tagged during removal
     
    TAC module electrical connector
     
    Radiator
     
    A/C compressor
     
    Fuel feed and return lines
     
    Ignition coils
     
    Positive, then negative battery cables
     
    Air cleaner outlet duct and secure with the clamp
     

  10.  
  11. Lower the hood from the service position.
  12.  
  13. Properly recharge the A/C system.
  14.  
  15. Fill the engine with oil.
  16.  
  17. Fill the engine with coolant.
  18.  
  19. Perform the Crankshaft Position (CKP) sensor variation learn procedure:
    1. Install a suitable scan tool and check for Diagnostic Trouble Codes (DTCs). If any DTCs, other than P1336 are set, resolve those codes first, before proceeding with this procedure.
    2.  
    3. With the scan tool, select the crankshaft position variation learn procedure.
    4.  
    5. Observe the fuel cut-off for the 8.1L engine.
    6.  
    7. The scan tool will instruct you to perform certain steps, make sure you follow all directions given by the scan tool exactly.
    8.  
    9. Enable the crankshaft position system variation learn procedure.
      NOTE
      While the learn procedure is in progress, release the throttle immediately when the engine started to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete.

    10.  
    11. Slowly increase the engine speed to the RPM that you observed.
    12.  
    13. Immediately release the throttle when fuel cut-out is reached.
    14.  
    15. The scan tool displays: Learn Status: Learned this ignition. If the scan tool does NOT display this message and not other DTCs set, you must perform further troubleshooting.
    16.  
    17. Turn the ignition OFF for 30 seconds after the learn procedure has been completed successfully.
    18.  

  20.  
  21. Start and run the engine, then check for leaks.
  22.  

  1. Raise the hood to the servicing position. Move the hood hinge bolt to hold the hood in the servicing position.
  2.  
  3. Release the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative, then positive battery cables
     
    Coolant
     
    A/C refrigerant
     
    Engine oil cooler lines from the engine block
     
    Transmission-to-engine bolts
     
    Clutch pressure plate bolts, if equipped
     
    Torque converter bolts, if equipped
     
    Catalytic converter
     
    Exhaust manifold pipe
     
    Hoses from power steering pump, then plug the lines and ports
     
    Starter motor
     




  6.  
  7. Raise the vehicle.

    Engine electrical harness and tie aside
     
    Alternator
     
    Ground cable bolt from engine block
     
    Exhaust Gas Recirculation (EGR) valve adapter
     
    Vacuum lines (tag before removal)
     
    Throttle Actuator Control (TAC) module electrical connector
     

  8.  
  9. Install Engine Lift Brackets part No. J 36857, or equivalent, to the rear of the right cylinder head and the front of the left cylinder head.

    Click image to see an enlarged view

    Fig. Install suitable lift brackets to the rear of the right head and the front of the left head

  10.  
  11. Install the attaching bolt and washer. Use part No. 9428217 with 1560963. Tighten the bolts to 30 ft. lbs. (40 Nm).
  12.  
  13. Remove or disconnect the following:

    Engine mount heat shield bolt and shields
     
    Engine mount-to-engine mount bracket bolts
     
    Engine from the vehicle, using a suitable lifting device. Place on a suitable stand.
     
    A/C compressor/power steering pump bracket from the cylinder head
     
    Lift brackets from the cylinder head
     

  14.  

To install:

  1. Install Engine Lift Brackets part No. J 36857, or equivalent, to the rear of the right cylinder head and the front of the left cylinder head.
  2.  
  3. Install the attaching bolt and washer. Use part No. 9428217 with 1560963. Tighten the bolts to 30 ft. lbs. (40 Nm).
  4.  
  5. Install or connect the following:

    A/C compressor/power steering mounting bracket. Tighten the bolts and nut to 37 ft. lbs. (50 Nm).
     
    Alternator bracket
     
    Engine into the vehicle
     
    Engine mount-to-engine mount bracket bolts
     
    Engine mount heat shield and bolts
     

  6.  
  7. Remove the lift hooks from the cylinder heads, then raise the vehicle.

    Engine oil cooler lines
     
    Transmission-to-engine bolts
     
    Clutch pressure plate bolts, if equipped
     
    Torque converter bolts, if equipped
     
    Catalytic converter
     
    Exhaust manifold pipe
     
    Hoses to the power steering pump
     
    Starter motor
     

  8.  
  9. Lower the vehicle.

    Engine electrical harness. Make sure the harness is properly routed.
     
    Alternator
     
    Ground cable bolt to engine block and tighten to 12 ft. lbs. (16 Nm)
     
    EGR valve adapter
     
    Vacuum lines, as tagged during removal
     
    TAC module electrical connector
     
    Radiator
     
    A/C compressor
     
    Fuel feed and return lines
     
    Ignition coils
     
    Positive, then negative battery cables
     
    Air cleaner outlet duct and secure with the clamp
     

  10.  
  11. Lower the hood from the service position.
  12.  
  13. Properly recharge the A/C system.
  14.  
  15. Fill the engine with oil.
  16.  
  17. Fill the engine with coolant.
  18.  
  19. Perform the Crankshaft Position (CKP) sensor variation learn procedure:
    1. Install a suitable scan tool and check for Diagnostic Trouble Codes (DTCs). If any DTCs, other than P1336 are set, resolve those codes first, before proceeding with this procedure.
    2.  
    3. With the scan tool, select the crankshaft position variation learn procedure.
    4.  
    5. Observe the fuel cut-off for the 8.1L engine.
    6.  
    7. The scan tool will instruct you to perform certain steps, make sure you follow all directions given by the scan tool exactly.
    8.  
    9. Enable the crankshaft position system variation learn procedure.
      NOTE
      While the learn procedure is in progress, release the throttle immediately when the engine started to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete.

    10.  
    11. Slowly increase the engine speed to the RPM that you observed.
    12.  
    13. Immediately release the throttle when fuel cut-out is reached.
    14.  
    15. The scan tool displays: Learn Status: Learned this ignition. If the scan tool does NOT display this message and not other DTCs set, you must perform further troubleshooting.
    16.  
    17. Turn the ignition OFF for 30 seconds after the learn procedure has been completed successfully.
    18.  

  20.  
  21. Start and run the engine, then check for leaks.
  22.  

 
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