CTS 2006-2007, CTS-V 2005-2007, DTS 2006-2007

Engine

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Removal & Installation



2.8L & 3.6L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Recover the A/C refrigerant.
  8.  
  9. Relieve the fuel system pressure.
  10.  
  11. Center the steering wheel and install Special Tool J-42640 Steering Column Anti-Rotation Pin to the steering column.
  12.  
  13. Remove or disconnect the following:
    WARNING
    Do NOT disconnect suction hose from A/C compressor.


    NOTE
    Do NOT disconnect the liquid line from the condenser.


    NOTE
    Do NOT disconnect the brake lines from the master cylinder.


    NOTE
    Do NOT remove the washer bottle.


    NOTE
    Cap the brake lines to minimize fluid loss.


    NOTE
    Secure the shock modules to the lower control arm with a strap to prevent damage to the front brake hoses.



    Negative battery cable
     
    Engine shroud
     
    Battery
     
    Air intake assembly
     
    Cooling fan wiring harnesses
     
    Surge tank hoses
     
    Heater hoses
     
    Vacuum hose from purge solenoid
     
    Fuel hose
     
    Wiper module
     
    A/C suction hose from the evaporator
     



    A/C pressure switch electrical connector and liquid line
     



    Radiator support brackets
     
    Brake booster vacuum hoses
     
    Brake fluid level switch electrical connector
     
    Mass air flow sensor electrical connector
     
    Engine wiring harnesses from the underhood electrical center
     
    Transmission control module (TCM) wiring harness
     
    Ground wire
     
    Master cylinder and secure to the engine
     



    Muffler assembly
     
    Driveshaft
     
    Air deflector
     
    Washer bottle bracket
     



    Radiator side baffles
     
    Left front brake line retainer
     
    Right front brake line from bundle
     
    Rear brake lines from the brake pressure modulator valve (BPVM)
     



    Front wheels
     
    Intermediate steering shaft
     
    Lower engine mount nuts
     
    Transmission shift linkage
     
    Low oil level sensor electrical connector. Secure to the engine mount bracket.
     
    Headlight leveling sensors
     
    Left and right shock module upper mounting bolts
     

  14.  
  15. Place a suitable lift table under the engine, transmission, front frame and front suspension assembly.
  16.  
  17. Position a suitable powertrain lift table below the frame, engine and transmission. Raise the lift table to support the frame, engine and transmission.
  18.  
  19. Remove the transmission brace and front frame mounting bolts.
  20.  
  21. Lower the lift table to remove the engine, transmission front frame and front suspension assembly.
  22.  
  23. Remove or disconnect the following:
    NOTE
    Cap the power steering lines to prevent fluid loss and contamination.



    Engine control module (ECM) harness
     
    Catalytic converters
     
    Thermostat housing with heater hoses, heater lines and surge tank hoses
     
    Starter motor
     
    Flywheel bolts
     
    Heater Oxygen sensor (HO2S) connector bracket from left cylinder head
     
    Remaining engine wiring harnesses
     
    Transmission oil cooler (TOC) lines
     
    Radiator hoses from water outlet and coolant inlet housing
     
    Power steering cooler hoses
     



    Condenser, radiator and fan module (CRFM) with radiator houses attached
     

  24.  
  25. Install engine lift brackets EN-46114 to the engine.
  26.  
  27. Attach an engine hoist to the lift brackets and partially support the engine. Position a second powertrain lift table below the transmission.
  28.  
  29. Remove or disconnect the following:

    Transmission
     
    Accessory drive belt
     
    Left and right drive belt tensioners
     
    Idler pulley
     
    Alternator and mounting bracket
     
    A/C compressor
     
    Power steering pump
     
    Power steering reservoir
     
    Oil level indicator tube
     
    Left exhaust manifold
     
    Oil filter adapter
     
    Right exhaust manifold
     
    Crankshaft pulley
     
    Flywheel
     
    Intake manifold
     
    Water outlet
     
    Block heater
     
    ECM and mounting bracket
     

  30.  
  31. Using the engine hoist, remove the engine assembly from the frame.
  32.  

To install:

  1. Using an engine hoist, lower the engine assembly to the frame.
  2.  
  3. Install or connect the following:

    ECM with the mounting bracket
     
    Water outlet
     
    Block heater
     
    Flywheel
     
    Intake manifold
     
    Crankshaft pulley. Tighten to 74 ft. lbs. (100 Nm) plus 150 degrees.
     
    Right exhaust manifold
     
    Oil filter adapter
     
    Left exhaust manifold
     
    Oil level indicator tube
     
    Alternator with mounting bracket
     
    Power steering pump
     
    Power steering reservoir
     
    A/C compressor
     
    Idler pulley. Tighten to 37 ft. lbs. (50 Nm).
     
    Left and right drive belt tensioners
     
    Accessory drive belt
     
    Transmission
     
    Flywheel-to-torque converter bolts
     
    Starter
     

  4.  
  5. Remove the engine lifting brackets from the engine.
  6.  
  7. Install or connect the following:

    CRFM with radiator hoses to the frame
     
    Power steering cooler hoses to the CRFM
     
    Radiator hoses to the water outlet and coolant inlet housing
     
    TOC lines
     
    Engine wiring harnesses
     
    HO2S connector bracket to the left cylinder head
     
    Thermostat housing with heater hoses, heater lines and surge tank hoses
     
    Catalytic converters
     
    Fuel lines
     
    ECM upper electrical connector
     

  8.  
  9. Raise the lift table to install the engine, transmission, front frame and front suspension assembly into the vehicle.
  10.  
  11. Install the front frame and transmission support mounting bolts. Tighten as follows:
    1. Front frame bolts: 141 ft. lbs. (191 Nm)
    2.  
    3. Transmission support bolts: 44 ft. lbs. (60 Nm)
    4.  

  12.  
  13. Remove the powertrain lift table.
  14.  
  15. Install or connect the following:

    Left and right shock module upper mounting bolts
     
    Headlight leveling sensors
     
    Transmission shift linkage
     
    Low oil level sensor electrical connector
     
    Lower engine mount nuts. Tighten to 59 ft. lbs. (80 Nm).
     
    Intermediate steering shaft
     
    Front wheels
     
    Brake lines
     
    Radiator side air baffles to the radiator
     
    Washer bottle bracket
     
    Air deflector
     
    Drive shaft
     
    Muffler assembly
     
    Brake master cylinder
     
    Ground wire
     
    TCM wiring harness
     
    Engine wiring harnesses to the underhood electrical connector
     
    Mass air flow sensor electrical connector
     
    Brake fluid level switch electrical sensor
     
    Brake booster vacuum hoses
     
    Radiator support brackets
     
    Vacuum hose to the purge solenoid
     
    Heater hoses
     
    Air intake assembly
     
    Surge tank lines
     
    A/C pressure switch electrical connector and liquid line to the evaporator
     
    A/C suction hose to the evaporator
     
    Cooling fan wiring harnesses
     
    Wiper module
     
    Battery and battery cables
     
    Engine shroud
     

  16.  
  17. Remove the steering column anti-rotation pin.
  18.  
  19. Fill and bleed the power steering system.
  20.  
  21. Refill the engine oil.
  22.  
  23. Fill and bleed the coolant system.
  24.  
  25. Recharge the A/C system and check for leaks.
  26.  
  27. Start the vehicle and inspect for leaks.
  28.  

4.6L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Recover the A/C refrigerant.
  8.  
  9. Remove the fuel injector sight shield.
  10.  
  11. Relieve the fuel system pressure.
  12.  
  13. Remove or disconnect the following:
    NOTE
    The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil assembly to become uncentered, which may cause damage to the coil assembly.



    Booster vacuum hose
     
    Fuel feed line
     
    Evaporative emission (EVAP) line
     
    Front compartment sight shield
     
    Air cleaner
     
    Starter cable from the BEC terminal and secure to the top of the engine
     
    Engine harness electrical connector from the Transaxle Control Module (TCM)
     
    Secure the TCM and engine harness wiring branches to the engine
     
    Engine harness electrical connectors from the engine control module (ECM).
     
    The junction block and bolts
     
    Engine harness from the BEC
     
    Right side frame rail ground strap, secure to engine
     
    Transaxle shift cable from the bracket and position the cable aside
     
    Radiator inlet and outlet hoses 
     
    Surge tank inlet hose
     
    Heater hoses
     
    Master cylinder, reposition the master cylinder and secure the master cylinder to the engine
     
    Transaxle oil cooler pipes from the radiator
     

  14.  
  15. Lock the steering column by installing the J 42640 into the underside of the steering column.
  16.  
  17. Remove the left and right side strut tower bolts.
  18.  
  19. Raise and support the vehicle. 
  20.  
  21. Remove or disconnect the following:
    WARNING
    Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or damage to the intermediate shaft. This damage may cause loss of steering control which could result in personal injury.


    NOTE
    Mark the flywheel to torque converter relationship prior to removal of the bolts.



    Rear exhaust manifold pipe
     
    Front wheels.
     
    Engine harness grommet from frame rail
     
    Engine harness clip from ride lever sensor
     
    Electronic suspension front position sensor, if equipped
     
    Front brake line brackets
     
    Rear brake lines from front lines, plug the open brake lines
     
    A/C compressor discharge and suction hoses at the condenser, secure to the engine and plug port
     



    Steering shaft cover
     
    Intermediate shaft pinch bolt and shaft
     
    The heated oxygen sensor (HO2S).
     
    Transaxle brace bolts and brace
     
    Torque converter cover
     



    Flywheel to torque converter bolts
     

  22.  
  23. Position the J 39580 engine cradle under the frame.
  24.  
  25. Lower the vehicle onto the J 39580.

    Click image to see an enlarged view

    Fig. J 39580 Engine support system

  26.  
  27. If the J 39580 is not available. Support the powertrain with four suitable jackstands.
  28.  
  29. Place a 2 inch x 4 inch block of wood between the front of the engine oil pan and the engine frame.
    WARNING
    To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

  30.  
  31. Secure the front hoist pads to the vehicle.
  32.  
  33. Remove the front fascia.
  34.  
  35. Remove the 6 bolts attaching the frame to the body.
  36.  
  37. Ensure clearance is maintained between the engine/transaxle assembly and the following:
    1. The A/C compressor components
    2.  
    3. The brake pipes
    4.  
    5. The heater hoses
    6.  
    7. The radiator hoses
    8.  
    9. The wheel speed sensor leads
    10.  

  38.  
  39. Carefully raise the vehicle in order to clear the supported engine/transaxle assembly.
  40.  
  41. Remove secondary Air Injection (AIR) components.
  42.  
  43. Remove the Ignition Control Module (ICM) ground strap from the right cylinder head.
  44.  
  45. Disconnect the following engine harness electrical connectors from the front of the engine:
    1. The fuel injectors 
    2.  
    3. The Ignition Control Module (ICM)
    4.  
    5. The Manifold Absolute Pressure (MAP) sensor
    6.  
    7. The throttle actuator
    8.  

  46.  
  47. Disconnect the following engine harness electrical connectors:
    1. The starter inline 
    2.  
    3. The AIR check valve
    4.  
    5. Power steering sensor
    6.  
    7. Engine harness electrical connector from the engine valley jumper
    8.  
    9. Engine harness ground 
    10.  
    11. Engine Coolant Temperature (ECT) sensor
    12.  
    13. Vehicle Speed Sensor (VSS)
    14.  
    15. A/C pressure sensor
    16.  
    17. Oil pressure sensor
    18.  
    19. Oil level sensor
    20.  
    21. The A/C compressor
    22.  
    23. Alternator
    24.  
    25. The AIR pump 
    26.  
    27. The brake modulator
    28.  
    29. HO2S sensor
    30.  

  48.  
  49. Remove all clips and retainers as needed.
  50.  
  51. Disconnect the engine harness electrical connector from the transaxle.
  52.  
  53. Remove all remaining engine harness ground bolts.
  54.  
  55. Gather all the branches of the engine harness and remove the engine harness from the engine.
  56.  
  57. Remove or disconnect the following:

    Power steering outlet hose from the reservoir
     
    Power steering inlet pipe fitting from the power steering pump
     
    A/C compressor discharge and suction hoses, plug ports
     
    Transaxle nuts, bolt and brace
     

  58.  
  59. Install an engine lift chain to the engine lift brackets and attach an engine lifting device.
  60.  
  61. Remove the rear engine mount to frame nut.
  62.  
  63. Remove the rear engine mount bracket bolts and stud.
  64.  
  65. Remove the rear engine mount bracket.
  66.  
  67. Remove the front engine mount to frame nut.
  68.  
  69. Remove the rear transaxle bolt.
  70.  
  71. Remove the upper transaxle bolts.
  72.  
  73. Separate the engine from the transaxle.
  74.  
  75. Raise the engine from the supported frame and transaxle assembly.
  76.  
  77. Remove the front engine mount bracket bolts/nuts.
  78.  
  79. Remove the front engine mount bracket.
  80.  
  81. Install the engine assembly to a suitable engine stand.
  82.  

To install:

  1. Install the front engine mount bracket.
  2.  
  3. Install the front engine mount bracket bolts/nuts and tighten to 37 ft. lbs. (50 Nm).
  4.  
  5. Install an engine lift chain to the engine lift brackets and attach an engine lifting device.
  6.  
  7. Remove the engine assembly from the engine stand.
  8.  
  9. Carefully position and install the engine to the supported frame and transaxle, aligning the engine dowel pins to the transaxle.
  10.  
  11. Install or connect the following:

    Upper transaxle bolts, Tighten to 55 ft. lbs. (75 Nm).
     
    Rear transaxle bolt. Tighten to 55 ft. lbs. (75 Nm).
     
    Front engine mount to frame nut. Tighten to 59 ft. lbs. (80 Nm).
     
    Rear engine mount bracket bolts and stud. Tighten the bolts/stud to 54 ft. lbs. (73 Nm).
     
    Rear engine mount to frame nut. Tighten the nut to 59 ft. lbs. (80 Nm).
     
    Transaxle brace
     
    Transaxle brace bolt. Tighten the bolt to 37 ft. lbs. (50 Nm).
     
    Front engine mount bracket nut with the transaxle brace behind it. Tighten the nut to 37 ft. lbs. (50 Nm).
     
    Transaxle brace to the engine and transaxle
     
    Transaxle brace bolts to the engine. Tighten the bolts to 37 ft. lbs. (50 Nm).
     
    Transaxle brace bolt/stud to the transaxle. Tighten the bolt/stud to 37 ft. lbs. (50 Nm).
     
    Transaxle brace to the lift bracket studs
     
    Transaxle brace bolt. Tighten the bolt/stud to 37 ft. lbs. (50 Nm). Tighten the nut to 37 ft. lbs. (50 Nm).
     
    A/C suction and discharge hoses. Remove plugs. Tighten to mounting nuts to 12 ft. lbs. (16 Nm).
     
    Power steering inlet pipe fitting to the power steering pump. Tighten the fitting to 20 ft. lbs. (27 Nm).
     
    Power steering inlet pipe bracket
     
    Power steering inlet pipe nut. Tighten the nut to 80 inch lbs. (9 Nm).
     
    Power steering outlet hose to the reservoir.
     
    Engine harness to the engine.
     
    Engine harness grounds. Tighten the bolts to 18 ft. lbs. (25 Nm). 
     
    Engine harness electrical connector to the transaxle
     

  12.  
  13. Connect the engine harness electrical connectors to the following:
    1. HO2S
    2.  
    3. The AIR pump
    4.  
    5. The brake modulator 
    6.  
    7. The oil pressure sensor
    8.  
    9. The oil level sensor
    10.  
    11. The A/C compressor
    12.  
    13. The alternator
    14.  
    15. A/C pressure sensor.
    16.  
    17. Vehicle Speed Sensor (VSS)
    18.  
    19. Engine Coolant Temperature (ECT) sensor
    20.  
    21. The power steering sensor
    22.  
    23. Engine valley jumper harness electrical connector.
    24.  

  14.  
  15. Connect the following engine harness electrical connectors to the top of the engine:
    1. The starter inline 
    2.  
    3. The AIR check valve
    4.  

  16.  
  17. Connect the following engine harness electrical connectors to the front of the engine:
    1. The fuel injectors 
    2.  
    3. The ICM
    4.  
    5. The MAP sensor 
    6.  
    7. The throttle actuator
    8.  

  18.  
  19. Connect the following engine harness electrical connectors to the rear of the engine:
    1. The EVAP solenoid 
    2.  
    3. The EGR valve 
    4.  
    5. The fuel injectors
    6.  
    7. The ICM 
    8.  

  20.  
  21. Install all clips and retainers as needed.
  22.  
  23. Install or connect the following:

    ICM ground strap bolt to the right cylinder head. Tighten the bolt to 18 ft. lbs. (25 Nm).
     
    Secondary air injection components.
     
    AIR pipe outlet pipe nut. Tighten the nut to 80 inch lbs. (90 Nm).
     
    Heater outlet pipe to the engine. Tighten the nut to 18 ft. lbs. (25 Nm).
     
    Heater outlet pipe at the water pump housing
     

  24.  
  25. Position the engine/transaxle assembly under the vehicle.
  26.  
  27. Ensure clearance is maintained between the engine/transaxle assembly and the following:
    1. The A/C compressor components
    2.  
    3. The brake pipes
    4.  
    5. The heater hoses
    6.  
    7. The radiator hoses
    8.  
    9. The wheel speed sensor leads
    10.  
    11. The wiring harnesses
    12.  

  28.  
  29. Carefully lower the vehicle over the engine/transaxle assembly, aligning the struts to the strut towers.
  30.  
  31. Install the 6 bolts attaching the frame to the body. Tighten the bolts to 141 ft. lbs. (191 Nm).
  32.  
  33. Install the front fascia.
  34.  
  35. Raise the vehicle off of the J 39580 or the jack stands.
  36.  
  37. Remove the J 39580 or jack stands from under the frame.
  38.  
  39. Align the flywheel with the marks made during the removal.
  40.  
  41. Install the flywheel to torque converter bolts. Tighten the bolts to 44 ft. lbs. (60 Nm).
  42.  
  43. Install or connect the following:
    WARNING
    When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation, the two mating shafts may disengage. Disengagement of the two mating shafts will cause loss of steering control which could result in personal injury.



    Torque converter cover. Tighten the bolt to 106 inch lbs. (12 Nm).
     
    Transaxle brace. Tighten the bolts to 35 ft. lbs. (47 Nm).
     
    HO2S
     
    Oxygen sensor wiring harness heat shield
     



    Intermediate shaft to the steering gear. Tighten the pinch bolt to 33 ft. lbs. (45 Nm).
     
    Intermediate steering shaft cover
     
    A/C compressor suction and discharge hoses to the condenser. Remove plugs. Install new washers and tighten the nut to 12 ft. lbs. (16 Nm).
     
    Rear brake lines to the front brake lines. Remove plugs. Tighten the fittings to 15 ft. lbs. (20 Nm).
     
    Left and right brake pipe bracket to the body frame rail. Tighten the nut to 80 inch lbs. (9 Nm).
     
    Front air deflector
     
    Electronic suspension front position sensor, if equipped.
     
    Engine harness grommet 
     
    Front wheels
     
    Rear exhaust manifold pipe
     

  44.  
  45. Lower the vehicle.
  46.  
  47. Remove the J 42640 from the steering column.
  48.  
  49. Install or connect the following:

    Transaxle oil cooler pipes to the radiator
     
    Upper transaxle oil cooler pipe bolt. Tighten the bolt to 53 inch. lbs. (6 Nm).
     
    Master cylinder. Tighten the nuts to 22 ft. lbs. (30 Nm).
     
    Heater inlet and outlet hoses to the heater pipes
     
    Surge tank inlet hose
     
    Radiator inlet and outlet hoses
     
    Transaxle shift cable
     
    Engine ground strap at frame rail. Tighten the bolt to 18 ft. lbs. (25 Nm).
     
    Engine harness to the BEC.
     
    The junction block. Tighten the bolts to 58 inch lbs. (6.5 Nm).
     
    Engine harness electrical connectors to the ECM
     
    Engine harness electrical connector to the body harness electrical connector
     
    Engine harness electrical connector to the TCM
     
    Starter cable to the BEC terminal. Tighten the nut to 11 ft. lbs. (15 Nm)
     
    Junction block cover
     
    The air cleaner
     
    Front compartment sight shield
     
    Fuel feed hose
     
    EVAP line
     
    Brake booster vacuum hose
     

  50.  
  51. Connect the negative battery cable.
  52.  
  53. Fill the engine with oil.
  54.  
  55. Fill the cooling system.
  56.  
  57. Bleed the brake system.
  58.  
  59. Recharge the A/C refrigerant system.
  60.  
  61. Bleed the power steering system.
  62.  
  63. Check the wheel alignment.
  64.  
  65. Pre-lube the engine.
  66.  
  67. Install the fuel injector sight shield.
  68.  
  69. With the ignition OFF or disconnected, crank the engine several times. Listen for any unusual noises or evidence that any parts are binding.
  70.  
  71. Start the engine and listen for abnormal conditions.
  72.  
  73. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
  74.  
  75. Run the engine at approximately 1000 RPM until the engine reaches normal operating temperature.
  76.  
  77. While the engine continues to idle raise and support the vehicle.
  78.  
  79. Inspect for oil, coolant and exhaust leaks while the engine is idling.
  80.  
  81. Lower the vehicle.
  82.  
  83. Perform the Crankshaft Position (CKP) system variation learn procedure.
  84.  
  85. Perform a final inspection for the proper engine oil and coolant levels.
  86.  
  87. Road test the vehicle.
  88.  

5.7L & 6.0L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Recover the A/C refrigerant.
  8.  
  9. Relieve the fuel system pressure.
  10.  
  11. Center the steering wheel and install Special Tool J-42640 Steering Column Anti-Rotation Pin to the steering column.
  12.  
  13. Remove or disconnect the following:
    NOTE
    Do NOT disconnect the lines from the cooler.


    NOTE
    Secure the shock modules to the front frame to avoid stretching the front brake hoses.



    Negative battery cable
     
    Shifter assembly mounting bolts
     
    Engine cross brace
     
    Engine shroud
     
    Air intake assembly
     
    Throttle body heater outlet hose from throttle body
     
    A/C suction hose from the evaporator
     
    A/C liquid line
     
    Brake booster vacuum hose from the brake booster
     
    Brake fluid level switch electrical connector
     
    Brake master cylinder mounting nuts and secure master cylinder to the engine with wire
     
    Electrical connectors from the top of right and left shock tower
     
    Chassis fuel line at the right rear of the engine
     
    Evaporative emissions (EVAP) hose at the right rear of the engine
     
    Engine wiring harness connector at the front of the dash
     
    Underhood fuse block wiring harness
     
    Battery
     
    Throttle actuator control (TAC) module
     
    Ground strap
     
    Electric cooling fan assembly
     
    A/C condenser assembly
     
    Power steering oil cooler mounting nuts and secure unit to the engine
     



    Front wheels
     
    Right front fender splash guard
     
    Windshield washer bottle-to-frame brace
     
    Separate the upper intermediate steering shaft from the center intermediate shaft
     
    Heater hoses
     
    Rear brake lines from the brake pressure modulator valve (BPMV)
     
    Transmission
     
    Clutch slave cylinder
     
    Rear brake lines from bundle clips
     
    Powertrain control module (PCM)
     
    Right and left shock module upper mounting bolts
     




  14.  
  15. Please a suitable lift table under the engine, front frame and front suspension assembly.
  16.  
  17. Raise the lift table to preload the weight of the engine, front frame and suspension assembly.
  18.  
  19. Remove the front frame bolts.
  20.  
  21. Lower the lift table and remove the engine, front frame and suspension assembly from the vehicle.
  22.  
  23. Using a suitable engine hoist, remove the engine from the front frame assembly.

    Click image to see an enlarged view

    Fig. Engine support fixture-5.7L

  24.  

To install:

  1. Lower the engine onto the front frame assembly.
  2.  
  3. Raise the engine, front frame and suspension assembly into the vehicle.
  4.  
  5. Install the frame bolts and tighten to 141 ft. lbs. (191 Nm).
  6.  
  7. Install the right and left shock module upper mounting bolts. Tighten to 83 ft. lbs. (112 Nm).
  8.  
  9. Remove the engine lift table.
  10.  
  11. Install or connect the following:

    PCM and wiring harness
     
    Rear brake lines into the bundle clips
     
    Clutch slave cylinder
     
    Transmission
     
    Rear brake lines to the BPMV
     
    Heater hoses
     
    Upper intermediate steering shaft to the center intermediate shaft
     
    Windshield washer bottle-to-frame brace
     
    Right fender splash guard
     
    Power steering hose and A/C suction hose to proper positions
     
    Power steering oil cooler. Tighten the bolts to 18 ft. lbs. (25 Nm).
     
    A/C condenser
     
    Radiator assembly
     
    Electric cooling fan assembly
     
    Ground strap
     
    Underhood fuse block wiring harness
     
    TAC module
     
    Electrical connectors to the top of the right and left shock towers
     
    Battery
     
    Engine wiring harness connect at the front of the dash
     
    Chassis-to-EVAP hose at the right rear of the engine
     
    Chassis fuel line at the right rear of the engine
     
    Brake master cylinder. Tighten the mounting nuts to 18 ft. lbs. (25 Nm).
     
    Brake fluid level switch electrical connector
     
    Brake booster vacuum line
     
    A/C liquid line
     
    A/C suction hose to the evaporator
     
    Throttle body heater outlet hose to the throttle body
     
    Air intake assembly
     
    Engine shroud
     
    Engine cross brace
     
    Shifter assembly mounting bolts. Tighten to 13 ft. lbs. (18 Nm).
     
    Battery cables
     

  12.  
  13. Remove the steering column anti-rotation pin.
  14.  
  15. Fill and bleed the power steering system.
  16.  
  17. Fill the transmission with fluid to the correct level.
  18.  
  19. Refill the engine oil.
  20.  
  21. Fill and bleed the coolant system.
  22.  
  23. Recharge the A/C system and check for leaks.
  24.  
  25. Start the vehicle and inspect for leaks.
  26.  

 
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