Escalade, Suburban, Tahoe, Yukon, Denali, DenaliXL, YukonXL 1999-2005

Engine

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Removal & Installation



3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the engine coolant.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Air intake assembly
     
    Hood
     
    Engine mount strut
     
    Accessory drive belt
     
    Knock sensor (KS) electrical connector
     
    Camshaft position (CMP) sensor electrical connector
     
    Crankshaft position (CKP) sensor electrical connector
     
    Heated oxygen sensor (HO2S) electrical connector
     
    Manifold absolute pressure (MAP) sensor electrical connector
     
    Exhaust gas recirculation (EGR) valve electrical connector
     
    Evaporative emission (EVAP) canister purge solenoid electrical connector
     
    Throttle control electrical connector
     
    Ignition coil electrical connector
     
    Body wiring harness
     

  10.  
  11. Raise and support the vehicle.
  12.  
  13. Remove or disconnect the following:

    Catalytic converters
     
    Engine wiring harness grounds
     
    Engine mount lower nuts
     
    Torque converter covers
     
    Starter
     
    A/C compressor mounting bolts and support the compress aside
     
    Torque converter bolts
     
    Transmission support brace
     
    Lower transmission-to-engine bolt
     
    Radiator hoses
     

  14.  
  15. Lower the vehicle and support the transmission.
  16.  
  17. Remove or disconnect the following:

    Heater hoses
     
    Vacuum hoses from upper intake manifold
     
    Fuel lines from the fuel rail
     

  18.  
  19. Install a suitable engine lifting device to the engine.
  20.  
  21. Remove the remaining transmission-to-engine bolts.
  22.  
  23. Remove the engine from the vehicle.
  24.  

To install:

  1. Install the engine to the transmission. Tighten the upper bolts to 55 ft. lbs. (75 Nm).
  2.  
  3. Remove the engine lifting device.
  4.  
  5. Install or connect the following:

    Radiator hoses
     
    Fuel lines to the fuel rail
     
    Brake booster vacuum hose to the upper intake manifold
     
    Heater hoses
     
    Lower transmission bolt and tighten to 55 ft. lbs. (75 Nm)
     
    Transmission support brace. Tighten bolts to 53 ft. lbs. (72 Nm)
     
    Torque converter bolts
     
    A/C compressor mounting bolts
     
    Starter
     
    Torque converter covers
     
    Engine mount lower nuts. Tighten nuts to 32 ft. lbs. (43 Nm).
     
    Engine wiring grounds. Tighten nut to 26 ft. lbs. (35 Nm).
     
    Catalytic converters
     
    Body wiring harness
     
    Ignition coil electrical connector
     
    Throttle control electrical connector
     
    EVAP canister purge solenoid electrical connector
     
    EGR valve electrical connector
     
    MAP sensor electrical connector
     
    HO2S electrical connector
     
    CKP sensor electrical connector
     
    CMP sensor electrical connector
     
    KS electrical connector
     
    Accessory drive belt
     
    Engine mount strut
     
    Hood
     
    Air intake assembly
     
    Negative battery cable
     

  6.  
  7. Fill the engine with oil to the correct level.
  8.  
  9. Fill the cooling system to the correct level.
  10.  
  11. Start the engine and check for leaks.
  12.  

4.3L, 5.0L & 5.7L Engines
  1. Drain the cooling system.
  2.  
  3. Drain the engine oil.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Hood
     
    Air cleaner
     
    Accessory drive belt
     
    Fan
     
    Water pump pulley
     
    Radiator and shroud
     
    Heater hoses at the engine
     
    Accelerator, cruise control and detent linkage if used
     
    Air conditioning compressor, if used, and lay aside
     
    Power steering pump, if used, and lay aside
     
    Wiring from the engine
     
    Fuel line
     
    Vacuum lines from the intake manifold
     
    Exhaust pipes from the manifold
     
    Strut rods at the engine mountings, if used
     
    Flywheel or torque converter cover
     
    Wiring along the oil pan rail
     
    Starter
     
    Wire for the fuel gauge
     
    Converter-to-flex plate bolts, if equipped with automatic transmission
     

  6.  
  7. Support the transmission

    Bell housing to engine bolts
     
    Rear engine mounting to frame bolts and the front through bolts and the 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).
     
    Bell housing to engine bolts and torque to 35 ft. lbs. (47 Nm)
     

  4.  
  5. Remove the transmission support.

    Converter-to-flex plate bolts and tighten to 35 ft. lbs. (47 Nm)
     
    Fuel gauge wiring
     
    Starter
     
    Flywheel or torque converter cover
     
    Strut rods at the engine mountings, if used
     
    Exhaust pipes at the manifold
     
    Vacuum lines to the intake manifold
     
    Fuel line
     
    Engine wiring harness
     
    Power steering pump, if used
     
    Air conditioning compressor, if used
     
    Accelerator, cruise control and detent linkage
     
    Heater hoses
     
    Radiator and shroud
     
    Accessory drive belts
     
    Hood
     
    Negative battery cable
     

  6.  
  7. Refill coolant and engine oil.
  8.  

4.8L, 5.3L & 6.0L Engines

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. Remove or disconnect the following:

    Negative battery cable
     
    Coolant
     
    A/C refrigerant
     

  2.  
  3. Raise the hood to the servicing position. Move the hood hinge bolt to hold the hood in the servicing position.
    CAUTION
    In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle. In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine.



    Upper and the lower radiator hoses from the engine
     
    Air cleaner duct from the engine
     
    A/C condenser mounting bolts
     
    Radiator support from the vehicle
     
    A/C compressor
     
    Coolant hose from the throttle body
     
    Heater hoses from the engine and the cowl
     
    Engine sight shield from the intake manifold
     
    Accelerator control cable mounting bracket from the intake manifold
     
    Accelerator control cable and the cruise control cable, if equipped, from the throttle shaft
     

  4.  
  5. Open the large electrical harness retainer. Remove one 10 mm nut in order to release the engine harness from the intake manifold.
  6.  
  7. Disconnect the electrical connectors from the following:

    Eight injectors
     
    Idle Air Control (IAC) motor
     
    Throttle Position (TP) sensor
     
    Evaporative Emissions (EVAP) canister purge solenoid
     
    Manifold Absolute Pressure (MAP) sensor
     
    Camshaft Position (CMP) sensor

    Click image to see an enlarged view

    Fig. Ignition coil removal-4.8L, 5.3L and 6.0L engines



    Click image to see an enlarged view

    Fig. Power steering pump removal-4.8L, 5.3L and 6.0L engines

     



    Ground splice at the rear of the right side of the block
     
    Ground splice and the ground strap at the rear of the left side of the block
     
    Coolant Temperature (CTS) sensor
     
    Oil pressure sensor/switch
     
    Electrical connector from intake and disconnect from harness
     
    Junction block bracket from alternator bracket
     

  8.  
  9. Set the electrical harness aside.
  10.  
  11. Remove or disconnect the following:

    EVAP canister purge solenoid vent tube from the solenoid by squeezing the retainer, then release the tube from the solenoid
     
    Battery negative cable from the engine block
     
    Drive belt
     
    Bolts holding the alternator mounting bracket to the cylinder head and block
     
    Bolt behind the power steering pump to engine block
     
    Alternator mounting bracket. Position the bracket aside.
     
    Fuel pipes from the engine

    Click image to see an enlarged view

    Fig. Power steering mount bracket removal-4.8L, 5.3L and 6.0L engines

     

  12.  
  13. Raise the vehicle.

    Steering linkage under body shield, if equipped
     
    Engine oil pan under body shield, if equipped
     
    Engine oil
     
    Starter motor

    Click image to see an enlarged view

    Fig. Bellhousing bolt removal-4.8L, 5.3L and 6.0L engines

     

  14.  
  15. Disconnect the engine wiring harness from the following components:

    Crankshaft Position (CKP) sensor
     
    Engine oil level sensor
     
    Block heater, if equipped
     
    Oil pan wiring harness
     

  16.  
  17. Reposition wiring from the lower engine area.

    Exhaust pipes from the exhaust manifolds
     
    Transmission cooler pipe retainer from the right side of the engine block, if equipped
     
    Torque converter shield from the engine
     
    Torque converter bolts
     
    Nut and the transmission oil level indicator tube from the bellhousing stud
     
    Lower bellhousing studs from the engine
     

  18.  
  19. Lower the vehicle.

    Remaining bellhousing bolts
     
    Engine electrical harness aside
     
    Ignition coil(s)
     

  20.  
  21. Install an engine crane.
  22.  
  23. Install a floor jack or stands to transmission for support.
  24.  
  25. Remove the engine mount bolts.
    NOTE
    Use care while moving the engine assembly in order to avoid breaking the MAP sensor locating tabs. Broken MAP sensor tabs may result in decreased engine performance.

  26.  
  27. Remove the engine from the vehicle.

    Click image to see an enlarged view

    Fig. Engine mount disconnect-4.8L, 5.3L and 6.0L engines

  28.  

To install:

  1. Install or connect the following:

    Engine to the vehicle
     
    Engine mount bolts
     
    Upper bellhousing bolts
     

  2.  
  3. Remove transmission support apparatus.
  4.  
  5. Remove the lifting device.
  6.  
  7. Remove the lift brackets from both cylinder heads.
  8.  
  9. Install the ignition coil(s) and the spark plug wire(s).
  10.  
  11. Route the engine wiring harness to the lower right hand side of the engine.
  12.  
  13. Raise the vehicle.
  14.  
  15. Install or connect the following:

    Remaining bellhousing bolts
     
    Torque converter bolts
     
    Torque converter shield
     
    Transmission oil level indicator tube and nut to bellhousing stud
     
    A/C compressor
     
    Transmission cooler pipe retainer to right side of engine block
     
    Engine exhaust pipes to the exhaust manifolds
     

  16.  
  17. Reroute wiring to lower engine area and install bolt to oil pan.
  18.  
  19. Connect electrical connectors to the CKP sensor, the engine oil level sensor and the block heater, if equipped.
  20.  
  21. Install or connect the following:

    Starter motor
     
    Engine oil pan under body shield, if equipped
     
    Steering linkage under body shield
     

  22.  
  23. Lower the vehicle.

    Fuel pipes to the engine
     
    Alternator mounting bracket to the cylinder head using the nuts and the bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).
     
    Bolt at the rear of the power steering pump to the engine block and tighten to 37 ft. lbs. (50 Nm)
     
    Alternator
     
    Drive belt
     
    Battery negative cable to the engine block
     
    EVAP canister purge solenoid to the intake manifold
     

  24.  
  25. Route the engine harness over the top of the engine. Attach the connectors for following components:
    CAUTION
    In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle. In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine.



    Eight injectors
     
    IAC motor
     
    TP sensor
     
    EVAP canister purge solenoid.
     
    MAP sensor
     
    CMP sensor
     
    Ground splice at the rear of the right side of engine block
     
    Ground splice and the ground strap at the rear of the left side of engine block
     
    CTS sensor
     

  26.  
  27. Install or connect the following:

    Nut to the engine wiring harness bracket and tighten to 89 inch lbs. (10 Nm)
     
    NEW accelerator control cable
     
    Cruise control cable, if equipped, to the throttle shaft
     
    Bolts for the accelerator control cable mounting bracket and tighten to 89 inch lbs. (10 Nm)
     
    Engine sight shield to the intake manifold
     
    Heater hoses to the cowl and the engine
     
    Coolant hose to the throttle body
     
    Radiator support in the vehicle
     
    A/C condenser mounting bolts
     
    Air cleaner duct
     
    Lower radiator hoses to the engine
     

  28.  
  29. Lower the hood.
  30.  
  31. Fill the engine with oil.
  32.  
  33. Fill the engine with coolant.
  34.  
  35. Connect the negative battery cable.
  36.  


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. Remove or disconnect the following:

    Negative battery cable
     
    Coolant
     
    A/C refrigerant
     

  2.  
  3. Raise the hood to the servicing position. Move the hood hinge bolt to hold the hood in the servicing position.
    CAUTION
    In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle. In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine.



    Upper and the lower radiator hoses from the engine
     
    Air cleaner duct from the engine
     
    A/C condenser mounting bolts
     
    Radiator support from the vehicle
     
    A/C compressor
     
    Coolant hose from the throttle body
     
    Heater hoses from the engine and the cowl
     
    Engine sight shield from the intake manifold
     
    Accelerator control cable mounting bracket from the intake manifold
     



    Accelerator control cable and the cruise control cable, if equipped, from the throttle shaft
     

  4.  
  5. Open the large electrical harness retainer. Remove one 10mm nut in order to release the engine harness from the intake manifold.
  6.  
  7. Disconnect the electrical connectors from the following:

    Eight injector connectors
     
    Idle Air Control (IAC) motor
     
    Throttle Position (TP) sensor
     
    Evaporative Emissions (EVAP) canister purge solenoid
     
    Manifold Absolute Pressure (MAP) sensor
     
    Camshaft Position (CMP) sensor

    Click image to see an enlarged view

    Fig. Ignition coil removal-4.8L, 5.3L and 6.0L engines

     
    Ground splice at the rear of the right side of the block
     
    Ground splice and the ground strap at the rear of the left side of the block

    Click image to see an enlarged view

    Fig. Power steering pump removal-4.8L, 5.3L and 6.0L engines

     
    Coolant Temperature Sensor (CTS)
     
    Oil pressure sensor/switch
     
    Intake electrical and disconnect from harness
     
    Junction block bracket from alternator bracket
     

  8.  
  9. Set the electrical harness aside.
  10.  
  11. Remove or disconnect the following:

    EVAP canister purge solenoid vent tube from the solenoid by squeezing the retainer, then release the tube from the solenoid
     
    Battery negative cable from the engine block
     
    Drive belt
     
    Bolts holding the alternator mounting bracket to the cylinder head and block
     
    Bolt behind the power steering pump to engine block
     
    Alternator mounting bracket and position the bracket aside
     
    Fuel pipes from the engine
     

  12.  
  13. Raise the vehicle.

    Steering linkage under body shield, if equipped
     
    Engine oil pan under body shield, if equipped
     
    Engine oil

    Click image to see an enlarged view

    Fig. Bellhousing bolt removal-4.8L, 5.3L and 6.0L engines

     
    Starter motor
     

  14.  
  15. Disconnect the engine wiring harness from the following components:

    Crankshaft Position (CKP) sensor
     
    Engine oil level sensor
     
    Block heater, if equipped
     
    Wiring harness from the oil pan
     
    Reposition wiring from lower engine area
     

  16.  
  17. Remove or disconnect the following:

    Exhaust pipes from the exhaust manifolds
     
    Transmission cooler pipe retainer from the right side of the engine block, if equipped
     
    Torque converter shield from the engine
     
    Torque converter bolts
     
    Nut and the transmission oil level indicator tube from the bellhousing stud
     
    Lower bellhousing studs from the engine
     

  18.  
  19. Lower the vehicle.

    Remaining bellhousing bolts
     
    Engine electrical harness; position aside
     
    Ignition coil(s)
     

  20.  
  21. Install an engine crane.
  22.  
  23. Install a floor jack or stands to transmission for support.
  24.  
  25. Remove the engine mount bolts.
    NOTE
    Use care while moving the engine assembly in order to avoid breaking the MAP sensor locating tabs. Broken MAP sensor tabs may result in decreased engine performance.

  26.  
  27. Remove the engine from the vehicle.
  28.  

To install:

  1. Install or connect the following:

    Engine to the vehicle
     
    Engine mount bolts
     
    Upper bellhousing bolts
     

  2.  
  3. Remove transmission support apparatus.
  4.  
  5. Remove the lifting device.
  6.  
  7. Remove the lift brackets from both cylinder heads.
  8.  
  9. Install the ignition coil(s) and the spark plug wire(s).
  10.  
  11. Route the engine wiring harness to the lower right hand side of the engine.
  12.  
  13. Raise the vehicle.
  14.  
  15. Install or connect the following:

    Remaining bellhousing bolts
     
    Torque converter bolts
     
    Torque converter shield
     
    Transmission oil level indicator tube and nut to bellhousing stud
     
    A/C compressor
     
    Transmission cooler pipe retainer to right side of engine block
     
    Engine exhaust pipes to the exhaust manifolds
     

  16.  
  17. Reroute wiring to lower engine area and install bolt to oil pan.
  18.  
  19. Install or connect the following:

    CKP sensor electrical connector
     
    Engine oil level sensor and the block heater electrical connectors, if equipped.
     
    Starter motor
     
    Engine oil pan under body shield, if equipped
     
    Steering linkage under body shield
     

  20.  
  21. Lower the vehicle.

    Fuel pipes to the engine
     
    Alternator mounting bracket to the cylinder head using the nuts and the bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).
     
    Bolt at the rear of the power steering pump to the engine block and tighten to 37 ft. lbs. (50 Nm).
     
    Alternator
     
    Drive belt
     
    Negative battery cable to the engine block
     
    EVAP canister purge solenoid to the intake manifold
     

  22.  
  23. Route the engine harness over the top of the engine. Attach the connectors to the following components:

    Eight injector connectors
     
    IAC motor
     
    TP sensor
     
    EVAP canister purge solenoid.
     
    MAP sensor
     
    CMP sensor
     
    Ground splice at the rear of the right side of engine block
     
    Ground splice and the ground strap at the rear of the left side of engine block
     
    CTS sensor
     
    Oil pressure sensor/switch
     

  24.  
  25. Install or connect the following:
    CAUTION
    In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle. In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine.



    Nut to the engine wiring harness bracket and tighten to 89 inch lbs. (10 Nm)
     



    NEW accelerator control cable
     
    Cruise control cable, if equipped, to the throttle shaft
     
    Bolts for the accelerator control cable mounting bracket and tighten to 89 inch lbs. (10 Nm)
     
    Engine sight shield to the intake manifold
     
    Heater hoses to the cowl and the engine
     
    Coolant hose to the throttle body
     
    Radiator support in the vehicle
     
    A/C condenser mounting bolts
     
    Air cleaner duct
     
    Lower radiator hoses to the engine
     

  26.  
  27. Lower the hood.
  28.  
  29. Fill the engine with oil.
  30.  
  31. Fill the engine with coolant.
  32.  
  33. Connect the negative battery cable.
  34.  

4.8L, 5.3L, 6.0L & 6.2L Engines

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. Remove or disconnect the following:

    Negative battery cable
     
    Coolant
     
    A/C refrigerant
     

  2.  
  3. Raise the hood to the servicing position. Move the hood hinge bolt to hold the hood in the servicing position.
    CAUTION
    In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle. In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine.



    Upper and the lower radiator hoses from the engine
     
    Air cleaner duct from the engine
     
    A/C condenser mounting bolts
     
    Radiator support from the vehicle
     
    A/C compressor
     
    Coolant hose from the throttle body
     
    Heater hoses from the engine and the cowl
     
    Engine sight shield from the intake manifold
     
    Accelerator control cable mounting bracket from the intake manifold
     



    Accelerator control cable and the cruise control cable, if equipped, from the throttle shaft
     

  4.  
  5. Open the large electrical harness retainer. Remove one 10 mm nut in order to release the engine harness from the intake manifold.
  6.  
  7. Disconnect the electrical connectors from the following:

    Eight injectors
     
    Idle Air Control (IAC) motor
     
    Throttle Position (TP) sensor
     
    Evaporative Emissions (EVAP) canister purge solenoid
     
    Manifold Absolute Pressure (MAP) sensor
     
    Camshaft Position (CMP) sensor

    Click image to see an enlarged view

    Fig. Ignition coil removal-4.8L, 5.3L, 6.0L and 6.2L engines

     



    Ground splice at the rear of the right side of the block
     
    Ground splice and the ground strap at the rear of the left side of the block
     
    Coolant Temperature (CTS) sensor
     
    Oil pressure sensor/switch
     
    Electrical connector from intake and disconnect from harness
     
    Junction block bracket from alternator bracket

    Click image to see an enlarged view

    Fig. Power steering pump removal-4.8L, 5.3L, 6.0L and 6.2L engines

     

  8.  
  9. Set the electrical harness aside.
  10.  
  11. Remove or disconnect the following:

    EVAP canister purge solenoid vent tube from the solenoid by squeezing the retainer, then release the tube from the solenoid
     
    Battery negative cable from the engine block
     
    Drive belt
     
    Bolts holding the alternator mounting bracket to the cylinder head and block
     
    Bolt behind the power steering pump to engine block

    Click image to see an enlarged view

    Fig. Power steering mount bracket removal-4.8L, 5.3L, 6.0L and 6.2L engines

     



    Alternator mounting bracket. Position the bracket aside.
     
    Fuel pipes from the engine
     

  12.  
  13. Raise the vehicle.

    Steering linkage under body shield, if equipped
     
    Engine oil pan under body shield, if equipped
     
    Engine oil
     
    Starter motor

    Click image to see an enlarged view

    Fig. Bell housing bolt removal-4.8L, 5.3L, 6.0L and 6.2L engines

     

  14.  
  15. Disconnect the engine wiring harness from the following components:

    Crankshaft Position (CKP) sensor
     
    Engine oil level sensor
     
    Block heater, if equipped
     
    Oil pan wiring harness
     

  16.  
  17. Reposition wiring from the lower engine area.

    Exhaust pipes from the exhaust manifolds
     
    Transmission cooler pipe retainer from the right side of the engine block, if equipped
     
    Torque converter shield from the engine
     
    Torque converter bolts
     
    Nut and the transmission oil level indicator tube from the bell housing stud
     
    Lower bell housing studs from the engine
     

  18.  
  19. Lower the vehicle.

    Remaining bell housing bolts
     
    Engine electrical harness aside
     
    Ignition coil(s)
     

  20.  
  21. Install an engine crane.
  22.  
  23. Install a floor jack or stands to transmission for support.
  24.  
  25. Remove the engine mount bolts.
    NOTE
    Use care while moving the engine assembly in order to avoid breaking the MAP sensor locating tabs. Broken MAP sensor tabs may result in decreased engine performance.

  26.  
  27. Remove the engine from the vehicle.

    Click image to see an enlarged view

    Fig. Engine mount disconnect-4.8L, 5.3L, 6.0L and 6.2L engines

  28.  

To install:

  1. Install or connect the following:

    Engine to the vehicle
     
    Engine mount bolts
     
    Upper bell housing bolts
     

  2.  
  3. Remove transmission support apparatus.
  4.  
  5. Remove the lifting device.
  6.  
  7. Remove the lift brackets from both cylinder heads.
  8.  
  9. Install the ignition coil(s) and the spark plug wire(s).
  10.  
  11. Route the engine wiring harness to the lower right hand side of the engine.
  12.  
  13. Raise the vehicle.
  14.  
  15. Install or connect the following:

    Remaining bell housing bolts
     
    Torque converter bolts
     
    Torque converter shield
     
    Transmission oil level indicator tube and nut to bell housing stud
     
    A/C compressor
     
    Transmission cooler pipe retainer to right side of engine block
     
    Engine exhaust pipes to the exhaust manifolds
     

  16.  
  17. Reroute wiring to lower engine area and install bolt to oil pan.
  18.  
  19. Connect electrical connectors to the CKP sensor, the engine oil level sensor and the block heater, if equipped.
  20.  
  21. Install or connect the following:

    Starter motor
     
    Engine oil pan under body shield, if equipped
     
    Steering linkage under body shield
     

  22.  
  23. Lower the vehicle.

    Fuel pipes to the engine
     
    Alternator mounting bracket to the cylinder head using the nuts and the bolts. Tighten the bolts to 37 ft. lbs. (50 Nm).
     
    Bolt at the rear of the power steering pump to the engine block and tighten to 37 ft. lbs. (50 Nm)
     
    Alternator
     
    Drive belt
     
    Battery negative cable to the engine block
     
    EVAP canister purge solenoid to the intake manifold
     

  24.  
  25. Route the engine harness over the top of the engine. Attach the connectors for following components:

    Eight injectors
     
    IAC motor
     
    TP sensor
     
    EVAP canister purge solenoid.
     
    MAP sensor
     
    CMP sensor
     
    Ground splice at the rear of the right side of engine block
     
    Ground splice and the ground strap at the rear of the left side of engine block
     
    CTS sensor
     

  26.  
  27. Install or connect the following:
    CAUTION
    In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle. In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine.



    Nut to the engine wiring harness bracket and tighten to 89 inch lbs. (10 Nm)
     



    NEW accelerator control cable
     
    Cruise control cable, if equipped, to the throttle shaft
     
    Bolts for the accelerator control cable mounting bracket and tighten to 89 inch lbs. (10 Nm)
     
    Engine sight shield to the intake manifold
     
    Heater hoses to the cowl and the engine
     
    Coolant hose to the throttle body
     
    Radiator support in the vehicle
     
    A/C condenser mounting bolts
     
    Air cleaner duct
     
    Lower radiator hoses to the engine
     

  28.  
  29. Lower the hood.
  30.  
  31. Fill the engine with oil.
  32.  
  33. Fill the engine with coolant.
  34.  
  35. Connect the negative battery cable.
  36.  

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.  

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.  

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.  

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. 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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