Engine Replacement

Engine Replacement
^ Tools Required
- J 41798 Engine Lifting Brackets
- J 21366 Converter Holding Strap

Removal Procedure





1. Open the hood.
2. Place fender covers over both fenders.
3. Raise the hood to the service position, then perform the following:
1. Remove the hood hinge bolts (1).
2. Raise the hood until vertical.
3. Install the hood hinge bolts until snug in the service position (2).
4. Remove the air conditioning (AC) compressor.
5. Remove the radiator supports.





6. Reposition the radiator inlet hose clamp at the water pump.
7. Remove the radiator inlet hose from the water pump.





8. Reposition the radiator outlet hose clamp at the water pump.
9. Remove the radiator outlet hose from the water pump.
10. Remove the heater hoses.





11. If equipped with the 4.8L, 5.3L, or 6.0L regular production option (RPO) LQ4, loosen the intake manifold sight shield bolt.
12. Remove the sight shield from the retainer.





13. If equipped with the 6.0L with RPO LQ9, perform the following:
1. Loosen the intake manifold sight shield bolt.
2. Loosen the left fuel rail cover bolts.
3. Remove the left fuel rail cover.
4. Loosen the right fuel rail cover bolts.
5. Remove the right fuel rail cover.
6. Remove the sight shield from the retainer.





14. Disconnect the following electrical connectors:
^ Evaporative emissions (EVAP) canister purge solenoid (1)
^ Generator (3)
15. Remove the harness bracket nut (2) in order to remove the engine harness from the intake manifold.





16. Reposition the vent inlet hose clamp at the throttle body.
17. Remove the radiator vent inlet hose from the throttle body.





18. Remove the generator cable from the generator, perform the following:
0. Slide the boot down revealing the terminal stud.
1. Remove the generator cable nut from the terminal stud.
2. Remove the generator cable.





19. Disconnect the main coil harness (2) and fuel injector (3) electrical connectors on the left side.





20. Remove the connector position assurance (CPA) retainer (5).
21. Disconnect the following electrical connectors:
^ The main coil harness (4)
^ The fuel injectors (3)
^ The electronic throttle control (ETC) (2)





22. Disconnect the manifold absolute pressure (MAP) sensor (1) and knock sensor (2) electrical connectors.





23. Remove the harness ground bolt.
24. Reposition the harness ground and negative battery cable from the block.
25. Disconnect the following electrical connectors:
^ The coolant temperature sensor (5)
^ The electronic variable orifice switch





26. Remove the harness ground bolt at the right rear of the engine block.
27. Reposition the harness ground, and auxiliary negative battery cable, if equipped from the block.
28. Remove the harness ground bolt at the left rear of the engine block.
29. Reposition the harness ground, and engine ground strap from the block.
30. Disconnect the following electrical connectors:
^ The oil pressure sensor (1)
^ The camshaft position (CMP) sensor (3)
31. Unclip all of the engine harness clips from the engine.





32. Remove the battery cable junction block from the junction block bracket.





33. Remove the EVAP purge solenoid vent tube, perform the following:
0. Remove the EVAP tube end from the solenoid (1).
1. Remove the EVAP tube end from the vapor pipe (2).
34. Disconnect the fuel pipes.
35. Raise the vehicle.





36. Disconnect the following electrical connectors:
^ The crankshaft position (CKP) sensor (1)
^ The engine oil level sensor (3)
^The coolant heater, if equipped





37. Remove the battery cable channel bolt.
38. Slide the channel pin out of the oil pan tab.
39. Gather all branches of the engine wiring harness and reposition off to the side.
40. Lower the vehicle.





41. Remove the rear power steering pump-to-engine block bolt.
42. Remove the generator bracket mounting bolts.
43. Position the bracket aside.





44. Remove the vacuum brake booster hose.
45. Remove the ignition coil, as required for the proper fit of the J 41798 before lifting the engine.





46. Notice: Refer to Fastener Notice in Service Precautions.

Install the J 41798 to the cylinder heads.
^ Tighten the M8 engine lift bracket bolts to 25 Nm (18 ft. lbs.).
^ Tighten the M10 engine lift bracket bolts to 50 Nm (37 ft. lbs.).





47. Remove the left and right engine mount-to-engine mount bracket bolts.
48. Raise and suitably support the vehicle. Refer to Vehicle Lifting.





49. Remove the engine shield bolts and shield.





50. Remove the oil pan skid plate bolts and plate, if equipped.
51. Drain the engine oil.
52. Remove the starter motor.
53. Remove the catalytic converter.





54. Remove the positive battery cable clip bolt and clip.





55. Remove the flywheel to torque converter bolts.





56. Remove the transmission oil level indicator tube nut, if equipped.





57. Remove the transmission oil level indicator tube, if equipped.





58. If equipped with the 4L60-E automatic transmission, remove the transmission bolt and stud on the right side.





59. If equipped with the 4L80-E automatic transmission, remove the transmission converter cover bolts.





60. Remove the automatic transmission bolt/studs, if equipped.
61. Separate the engine from the automatic transmission.Install the J 21366 to the transmission in order to hold the torque converter.
62. Lower the vehicle.
63. Install an engine hoist to the J 41798.
64. Install a floor jack under the transmission for support.

Notice: 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.

65. Remove the engine.
66. Install the engine to an engine stand.
67. Remove the engine hoist.





68. Remove the J 41798 from the engine.

Installation Procedure





1. Notice: Refer to Fastener Notice in Service Precautions.

Install the J 41798 to the engine.
^ Tighten the M8 engine lift bracket bolts to 25 Nm (18 ft. lbs.).
^ Tighten the M10 engine lift bracket bolts to 50 Nm (37 ft. lbs.).
2. Install an engine hoist to the J 41798.
3. Remove the engine from the engine stand.
4. Install the engine to the vehicle.
5. Align the engine and transmission.





6. Install the left and right engine mount-to-engine mount bracket bolts.
^ Tighten the engine mount-to-engine mount bracket bolts to 65 Nm (48 ft. lbs.).
7. Install the upper transmission bolts until snug.
8. Remove the floor jack from under the transmission.
9. Remove the engine hoist.





10. Remove the J 41798 from the engine.





11. Install the ignition coils and the spark plug wires.
12. Raise the vehicle.





13. Remove the J 21366 from the transmission.
14. Install the automatic transmission bolt/studs.





15. If equipped with the 4L80-E automatic transmission, install the transmission converter cover bolts.





16. If equipped with the 4L60-E automatic transmission, install the transmission bolt and stud on the right side.
^ Tighten the automatic transmission bolts/studs to 50 Nm (37 ft. lbs.).





17. Install the automatic transmission oil level indicator tube.





18. Install the automatic transmission oil level indicator tube nut.
^ Tighten the nut to 18 Nm (13 ft. lbs.).





19. Install the flywheel to torque converter bolts.
^ If equipped with a 4L60E transmission, tighten the bolts to 63 Nm (47 ft. lbs.).
^ If equipped with a 4L80E transmission, tighten the bolts to 60 Nm (44 ft. lbs.).





20. Install the positive battery cable clip and bolt.
^ Tighten the bolt to 9 Nm (80 inch lbs.).
21. Install the catalytic converter.
22. Install the starter motor.





23. Install the oil pan skid plate and bolts, if equipped.
^ Tighten the bolts to 20 Nm (15 ft. lbs.).





24. Install the engine shield and bolts.
^ Tighten the bolts to 20 Nm (15 ft. lbs.).
25. Lower the vehicle.





26. Install the vacuum brake booster hose.





27. Position the generator bracket to the front of the engine.
28. Install the generator bracket bolts until snug.
29. Install the rear power steering pump-to-engine block bolt until snug.
^ Tighten the rear power steering pump bolt to 50 Nm (37 ft. lbs.).
^ Tighten the generator bracket bolts to 50 Nm (37 ft. lbs.).
30. Route the engine wiring harness to the lower engine area.
31. Raise the vehicle.





32. Slide the channel pin into the oil pan tab.
33. Install the battery cable channel bolt.
^ Tighten the bolt to 12 Nm (106 inch lbs.).





34. Connect the following electrical connectors:
^ The CKP sensor (1)
^ The engine oil level sensor (3)
^ The coolant heater, if equipped
35. Lower the vehicle.
36. Connect the fuel pipes.





37. Install the EVAP purge solenoid vent tube to the solenoid (1).
38. Install the EVAP tube end to the vapor pipe (2).





39. Install the battery cable junction block to the junction block bracket.
40. Clip all of the engine wiring harness clips to their correct location.





41. Connect the following electrical connectors:
^ The oil pressure sensor (1)
^ The CMP sensor (3)
42. Position the harness ground and the engine ground strap to the block.
43. Install the harness ground bolt at the left rear of the engine block.
44. Position the harness ground, and auxiliary negative battery cable, if equipped to the block.
45. Install the harness ground bolt at the right rear of the engine block.
^ Tighten the bolts to 16 Nm (12 ft. lbs.).





46. Connect the following electrical connectors:
^ The coolant temperature sensor (5)
^ The electronic variable orifice switch
47. Position the harness ground and negative battery cable to the block.
48. Install the harness ground bolt.
^ Tighten the bolt to 25 Nm (18 ft. lbs.).





49. Connect the MAP sensor (1) and knock sensor (2) electrical connectors.





50. Connect the following electrical connectors:
^ The main coil harness (4)
^ The fuel injectors (3)
^ The ETC (2)
51. Install the CPA retainer (5).





52. Connect the main coil harness (2) and fuel injector (3) electrical connectors on the left side.





53. Install the generator cable to the generator, perform the following:
1. Install the generator cable.
2. Install the generator cable nut to the terminal stud.
^ Tighten the nut to 9 Nm (80 inch lbs.).
3. Slide the boot over the terminal stud.





54. Install the radiator vent inlet hose to the throttle body.
55. Position the vent inlet hose clamp at the throttle body.





56. Install the engine wiring harness bracket and nut (2).
^ Tighten the nut to 5 Nm (44 inch lbs.).
57. Connect the following electrical connectors:
^ The EVAP canister purge solenoid (1)
^ The Generator (3)





58. If equipped with the 6.0L with RPO LQ9, perform the following:
0. Install the right fuel rail cover.
1. Tighten the right fuel rail cover bolts.
^ Tighten the bolts to 9 Nm (80 inch lbs.).
2. Install the left fuel rail cover.
3. Tighten the left fuel rail cover bolts.
^ Tighten the bolts to 9 Nm (80 inch lbs.).
4. Install the sight shield to the retainer.
5. Tighten the intake manifold sight shield bolt.
^ Tighten the bolt to 10 Nm (89 inch lbs.).





59. If equipped with the 4.8L, 5.3L, or 6.0L with RPO LQ4, install the engine sight shield to the retainer.
60. Tighten the engine sight shield bolt.
^ Tighten the bolt to 10 Nm (89 inch lbs.).
61. Install the heater hoses.




62. Install the radiator outlet hose to the water pump.
63. Position the radiator outlet hose clamp at the water pump.





64. Install the radiator inlet hose to the water pump.
65. Position the radiator inlet hose clamp at the water pump.
66. Install the radiator supports.
67. Install the A/C compressor.





68. Remove the hood hinge bolts from the service position (2).
69. Lower the hood to the normal position.
70. Install the hood hinge bolts.
^ Tighten the bolts to 25 Nm (18 ft. lbs.).
71. Remove the fender covers.
72. Perform the engine prelubing procedure.
73. Perform the CKP system variation learn procedure.

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

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