Tools Required

1. Disconnect the positive battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.



2. Disconnect the intake air temperature (IAT) sensor electrical connector.
3. Disconnect the mass airflow (MAF) sensor electrical connector.



4. Remove the air intake duct resonator.
5. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.
6. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure in Engine Controls.
7. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information



8. Remove the oil pan drain plug.
9. Drain the engine oil.
10. Remove the front wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
11. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
12. Remove the left catalytic converter. Refer to Oxidation Catalytic Converter Replacement in Engine Exhaust.
13. Remove the right catalytic converter. Refer to Oxidation Catalytic Converter Replacement in Engine Exhaust
14. Drain the transmission fluid, if equipped with a manual transmission.
15. Remove the propeller shaft. Refer to One-Piece Propeller Shaft Replacement in Propeller Shaft.
16. Remove the torque arm. Refer to Torque Arm Replacement in Rear Suspension.
17. Remove the starter motor. Refer to Starter Motor Replacement in Engine Electrical.



18. On vehicles equipped with a automatic transmission, unsnap the transmission range selector lever cable from the range selector lever at the transmission.



19. Remove the retainer from the range selector lever cable.



20. Remove the range selector lever cable from the cable bracket.



21. On vehicles equipped with a manual transmission, disconnect the clutch actuator cylinder line from the actuator cylinder using J 36221 .
22. Remove the left side front air deflector. Refer to Front Bumper Fascia Air Deflector Replacement in Bumpers.
23. Remove the stabilizer bar bracket bolts.
24. Remove the stabilizer bar brackets.



25. Remove the intermediate steering shaft bolt and shaft from the rack.



26. Remove the wiring harness ground bolt and RF (Radio Frequency) ground strap and cruise control ground lead from the front rail.



27. Disconnect the wheel speed sensor electrical connectors.



28. Remove the air conditioning (A/C) compressor and condenser hose bolt.
29. Discard the O-ring.



30. Remove the front fuel pipe heat shield nuts (1).
31. Remove the front fuel pipe heat shield (2).
32. Disconnect the brake lines from the brake pipe clip.
33. Lower the vehicle.



34. Remove the A/C compressor and condenser hose bolt at the accumulator.
35. Discard the O-ring.



36. Remove the inlet and outlet heater hoses from the water pump.

36.1.

Squeeze the hose clamp together with pliers.

36.2.

Slide the hose clamp away from the water pump fitting.

36.3.

Gently twist and pull the heater hose from the water pump fitting.




37. Disconnect the fuel line from the fuel rail.
38. Disconnect the vapor line from the fuel vapor purge valve.



39. Remove the cruise control cable from the throttle lever.

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. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.



40. Remove the accelerator control cable from the throttle lever.
41. Unsnap and remove the accelerator and cruise control cable from the throttle body bracket.



42. Remove the cruise control and accelerator control cables from the servo adjuster, if equipped.



43. Remove the outlet hose from the water pump.



44. Remove the inlet hose from the water inlet.
45. Remove the brake booster vacuum hose.
46. Remove the front two brake lines from the brake pressure modulator valve.



47. Disconnect the secondary captured locks.
48. Disconnect the forward lamp harness from the engine harness.
49. Disconnect the engine harness vacuum tube from the bottom of the vacuum check valve.



50. Disconnect the powertrain control module (PCM) connectors.
51. Remove the PCM from the vehicle.
52. Remove the right side insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Right Side in Instrument Panel, Gauges and Console.
53. Remove the hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement in Interior Trim.



54. Disconnect the engine wiring harness from the instrument panel wiring harness.



55. Remove the engine wire harness through the front of dash. Place the harness on top of the engine.
56. Remove the floor shift control, if equipped. Refer to Transmission Control Replacement in Automatic Transmission - 4L60-E.
57. Remove the transmission control, if equipped. Refer to Shift Control Assembly Replacement in Manual Transmission - MM6.
58. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



59. Remove the right and left side shock absorber lower mounting bolts.
60. Remove the cotter pins and nuts from the left and right upper ball joints.
61. Using J 39549 separate the upper control arms from the steering knuckles.
62. Support both steering knuckles.
63. Position the J 39580 below the vehicle.
64. Lower the vehicle until the crossmember is resting on the J 39580 .
65. Lay the engine wire harness on top of the engine.



66. Remove the front crossmember bolts.



67. Remove the transmission support bolts.
68. Raise the vehicle and remove the engine and transmission from the vehicle.
69. Secure the crossmember to the J 39580 .



70. Position a hex-head socket on the belt tensioner pulley bolt.
71. Rotate the drive belt tensioner clockwise to relieve the tension on the drive belt.
72. Remove the drive belt from the tensioner and pulleys.



73. Position a hex-head socket on the belt tensioner pulley bolt.
74. Rotate the air conditioning (A/C) drive belt tensioner clockwise to relieve the tension on the drive belt.
75. Remove the A/C drive belt from the crankshaft balancer and A/C compressor.



76. Disconnect the A/C compressor electrical connector.



77. Remove the A/C compressor bolts.
78. Remove the A/C compressor.



79. Remove the power steering pump bolts (4) and pump brace (3).
80. Remove the power steering pump (1) from the bracket (2).
81. Reposition the power steering pump to the crossmember.



82. Disconnect the generator electrical connector (3).



83. Remove the positive cable nut from the generator.
84. Remove the positive cable from the generator.
85. Install a engine hoist the block.



86. Remove the right side engine mount bracket to block bolts and bracket.



87. Remove the engine mount heat shield nuts.
88. Remove the engine mount heat shield.



89. Remove the left side engine mount bracket to block studs and bracket.
90. With the aide of an assistant, raise the engine and transmission from the crossmember.



91. Remove the harness clamp bolt (1).
92. Disconnect the following electrical connectors from the transmission:

•	20-way connector (2)

•	Vehicle speed sensor (3)

93. If equipped with an automatic transmission perform the following:



94. Remove the left side transmission closeout and bolt.



95. Remove the right side transmission closeout and bolt.



96. Remove the flywheel to torque converter bolts.



97. Remove the transmission to engine bolts.
98. Separate the transmission from the engine.
99. Attach the J 21366 to the transmission.
100. If equipped with a manual transmission, perform the following:



101. Remove the flywheel housing to engine bolts (2).
102. Separate the flywheel housing from the engine.



103. Remove the pressure plate bolts (4).
104. Remove the pressure plate (3) and clutch disc (2) from the flywheel (1).
105. Install the engine to a engine stand.
106. Remove the engine hoist.

Tools Required

J 38836 Pilot Bushing Installer/Clutch Alignment Arbor

1. Install a engine hoist to the block.
2. Remove the engine from the engine stand.
3. If equipped with a manual transmission, perform the following:
4. Install the clutch disc and pressure plate to the flywheel.
5. Install the pressure plate bolts finger tight.
6. Use the J 38836 to align the clutch disc splines with the pilot bearing.



7. Tighten the clutch pressure plate bolts.

Tighten
Tighten the clutch pressure plate bolts in sequence (as shown) and evenly over 3 increments with the fourth increment to 70 N·m (52 lb ft).

8. Remove the J 38836 .



9. Install the flywheel housing to engine bolts (2).

Tighten
Tighten the flywheel housing to engine bolts (2) to 50 N·m (37 lb ft).

10. If equipped with an automatic transmission perform the following:



11. Remove the J 21366 from the transmission.
12. Install the transmission to engine bolts.

Tighten
Tighten the transmission to engine bolts to 50 N·m (37 lb ft).




13. Install the flywheel to torque converter bolts.

Tighten
Tighten the flywheel to torque converter cover bolts to 60 N·m (44 lb ft).




14. Install the right side transmission closeout and bolt.

Tighten
Tighten the right side closeout bolt to 12 N·m (106 lb in).




15. Install the left side transmission closeout and bolt.

Tighten
Tighten the left side closeout bolt to 12 N·m (106 lb in).




16. Connect the following electrical connectors to the transmission:

•	20-way connector (2)

•	Vehicle speed sensor (3)

17. Install the harness clamp bolt (1).

Tighten
Tighten the harness clamp bolt (1) to 2.5 N·m (22 lb in).

18. With the aide of an assistant, lower the engine and transmission to the crossmember.



19. Install the left side engine mount bracket and studs.

Tighten
Tighten the engine mount bracket studs to 50 N·m (37 lb ft).




20. Install the engine mount heat shield.
21. Install the engine mount heat shield nuts.

Tighten
Tighten the engine mount heat shield nuts to 10 N·m (89 lb ft).




22. Install the right side engine mount bracket and bolts.

Tighten
Tighten the engine mount bracket bolts to 50 N·m (37 lb ft).

23. Remove the hoist from the engine.



24. Install the positive cable to the generator.
25. Install the positive cable nut to the generator.

Tighten
Tighten the positive cable nut to the generator to 22 N·m (16 lb ft).




26. Connect the generator electrical connector (3).



27. Install the power steering pump (1) to the bracket (2).
28. Install the power steering brace (3) and bolts (4).

Tighten
Tighten the power steering pump bolts (4) to 25 N·m (18 lb ft).




29. Install the A/C compressor.
30. Install the A/C compressor bolts.

Tighten
Tighten the A/C compressor bolts to 50 N·m (37 lb ft).




31. Connect the A/C compressor electrical connector.



32. Route the A/C belt over the crankshaft balancer.
33. Rotate the A/C drive belt tensioner clockwise to relieve the tension.
34. Install the drive belt between the idler and over the tensioner (1) and onto the compressor pulley.



35. Route the drive belt around the pulleys.
36. Position the hex-head socket on the belt tensioner pulley bolt.
37. Rotate the drive belt tensioner clockwise to relieve tension.
38. Install the drive belt around the tensioners.
39. Remove the strap from the crossmember to the J 39580 .
40. Lower the vehicle and install the engine and transmission to the vehicle.



41. Install the transmission support bolts.

Tighten
Tighten the transmission support bolts to 90 N·m (66 lb ft).




42. Install the front crossmember bolts.

Tighten

•	Tighten the four upper crossmember bolts to 125 N·m (92 lb ft).

•	Tighten the two lower crossmember bolts to 145 N·m (107 lb ft).

43. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
44. Remove the J 39580 from below the vehicle.
45. Remove the support from both steering knuckles.
46. Install the upper control arm ball studs to the steering knuckles.
47. Install the nuts to the left and right upper ball joints.

Tighten
Tighten the upper control arm nuts to 53 N·m (39 lb ft).

48. Install cotter pins to the upper control arm nuts.



49. Install the right and left side shock absorber lower mounting bolts.

Tighten
Tighten the shock absorber bolts to 65 N·m (48 lb ft).

50. Lower the vehicle.
51. Install the transmission control, if equipped. Refer to Shift Control Assembly Replacement in Manual Transmission - MM6.
52. Install the floor shift control, if equipped. Refer to Transmission Control Replacement in Automatic Transmission - 4L60-E.



53. Install the engine wire harness through the front of dash.



54. Connect the engine wiring harness to the I/P wiring harness.
55. Install the hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel Replacement in Interior Trim.
56. Install the right side insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Right Side in Instrument Panel, Gauges and Console.
57. Install the PCM to the vehicle.



58. Connect the PCM connectors to the PCM.

Tighten
Tighten the PCM connector bolts to 8 N·m (71 lb in).




59. Connect the engine harness vacuum tube to the bottom of the vacuum check valve.
60. Connect the forward lamp harness to the engine harness.
61. Connect the secondary captured locks.
62. Install the front two brake pipes to the brake pressure modulator valve.
63. Install the brake booster vacuum hose.



64. Install the inlet hose to the water inlet.



65. Install the outlet hose to the water pump.



66. Install the cruise control and accelerator control cables to the servo adjuster, if equipped.

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. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.



67. Install the accelerator control cable to the throttle body bracket.
68. Install a NEW accelerator control cable to the throttle lever.



69. Install the cruise control cable to the throttle lever.



70. Connect the fuel line to the fuel rail.
71. Connect the vapor line to the fuel vapor purge valve.



72. Install the inlet and outlet heater hoses to the water pump.



73. Install a new O-ring.
74. Install the A/C compressor and condenser hose bolt at the accumulator.

Tighten
Tighten the A/C compressor and condenser hose bolt to 16 N·m (12 lb ft).

75. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



76. Connect the brake lines to the brake pipe clip.
77. Install the front fuel pipe heat shield (2).
78. Install the front fuel pipe heat shield nuts (1).

Tighten
Tighten the front fuel pipe heat shield nuts (1) to 5 N·m (44 lb in).




79. Install a new O-ring.
80. Install the A/C compressor and condenser hose nut at the condenser.

Tighten
Tighten the A/C compressor and condenser hose nut at the condenser to 16 N·m (12 lb ft).




81. Install a new O-ring.
82. Install the A/C compressor and condenser hose bolt.

Tighten
Tighten the A/C compressor and condenser hose bolt to 33 N·m (24 lb ft).




83. Connect the wheel speed sensor electrical connectors.



84. Install the RF ground strap and cruise control ground lead from the front rail.
85. Install the wiring harness ground bolt.

Tighten
Tighten the wiring harness ground bolt to 12 N·m (106 lb in).




86. Install the intermediate steering shaft and shaft bolt to the rack.

Tighten
Tighten the intermediate steering shaft bolt to 47 N·m (35 lb ft).

87. Install the stabilizer bar brackets.
88. Install the stabilizer bar bracket bolts.

Tighten
Tighten the stabilizer bar bracket bolts to 55 N·m (41 lb ft).

89. Install the left side front air deflector. Refer to Front Bumper Fascia Air Deflector Replacement in Bumpers.



90. On vehicles equipped with a manual transmission, connect the clutch actuator cylinder line to the actuator cylinder.



91. On vehicles equipped with a automatic transmission, install the range selector lever cable to the cable bracket.



92. Install the retainer to the range selector lever cable.



93. Snap the transmission range selector lever cable to the range selector lever at the transmission.
94. Install the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
95. Install the torque arm. Refer to Torque Arm Replacement in Rear Suspension.
96. Install the propeller shaft. Refer to One-Piece Propeller Shaft Replacement in Propeller Shaft.
97. Install the right side catalytic converter. Refer to Oxidation Catalytic Converter Replacement in Engine Exhaust.
98. Install the left side catalytic converter. Refer to Oxidation Catalytic Converter Replacement in Engine Exhaust.
99. Install the front wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
100. Lower the vehicle.



101. Install the air intake duct resonator.



102. Connect the IAT sensor electrical connector.
103. Connect the MAF sensor electrical connector.



104. Connect the positive battery cable.
105. Refill the engine oil.
106. Refill the transmission fluid.
107. Recharge the refrigerant. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.
108. Bleed the brakes. Refer to Hydraulic Brake System Bleeding or Hydraulic Brake System Bleeding in Hydraulic Brakes.
109. Bleed the clutch hydraulic system. Refer to Clutch Pedal Replacement in Clutch.
110. Perform the crankshaft position (CKP) system variation learn procedure. Refer to Crankshaft Position System Variation Learn in Engine Controls - 5.7 L.