Tools Required

1. Center the steering wheel.
2. Turn the ignition OFF.



3. Install the J 42640 to the steering column. Refer to Lower Intermediate Steering Shaft Replacement in Steering Wheel and Column for more information.




Important: Do NOT disconnect the battery cable from the engine.

4. Disconnect the battery negative cable from the battery and the body. Refer to Battery Negative Cable Replacement in Engine Electrical.

Important: Do NOT disconnect the battery cable from the engine.

5. Disconnect the battery positive cable from the battery and the underhood electrical center. Refer to Battery Positive Cable Replacement in Engine Electrical.
6. Position and secure the battery cables to the engine.
7. Remove the battery. Refer to Battery Replacement in Engine Electrical.
8. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .



9. Remove the air cleaner duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 2.8L (LP1).



10. Disconnect the cooling fan electrical connectors (2 and 3).
11. Remove the cooling fan wiring harnesses (1 and 4) from the fan shroud.
12. Secure the wiring harnesses to the vehicle.
13. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.

Important: Do NOT disconnect the surge hoses from the engine or the radiator.

14. Disconnect the surge tank outlet hose from the surge tank. Refer to Radiator Surge Tank Inlet Hose/Pipe Replacement in Engine Cooling.
15. Position and secure the surge hose to the engine.
16. Disconnect the surge tank inlet (vent) hose from the water outlet housing and the radiator. Refer to Radiator Surge Tank Outlet Hose/Pipe Replacement in Engine Cooling.
17. Position and secure the surge tank inlet (vent) hose to the vehicle.
18. Disconnect the heater hoses from the heater core. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement in Heating, Ventilation and Air Conditioning.



19. Disconnect the purge line (3) from the purge solenoid.
20. Disconnect the fuel pipe (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service in Engine Controls - 2.8L (LP1).
21. Plug the fuel pipe and cap the fuel rail to prevent fuel loss and/or contamination.
22. Evacuate the air conditioning system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.
23. Remove the wiper module. Refer to Windshield Wiper System Module Replacement .

Important: Do NOT disconnect the suction hose from the A/C compressor.

24. Disconnect the air conditioning suction hose from the evaporator and remove the suction hose bracket from the shock tower. Refer to in Suction Hose Replacement Heating, Ventilation and Air Conditioning.
25. Position and secure suction hose to the engine.

Important: Do NOT disconnect the liquid line from the condenser.

26. Disconnect the air conditioning pressure switch electrical connector and remove the liquid line . Refer to Liquid Line Replacement in Heating, Ventilation and Air Conditioning.
27. Remove the radiator support brackets. Refer to Radiator Support Bracket Replacement in Engine Cooling.



28. Disconnect the brake booster check valve and vacuum hose (1) from the brake booster (2).
29. Position and secure the brake booster hose to the engine.
30. Disconnect the brake fluid level switch electrical connector from the master cylinder.
31. Disconnect the mass air flow sensor electrical connector.
32. Unlock and disconnect the instrument panel (I/P) electrical connector from the engine located at the rear of the left (Bank 2) cylinder head.
33. Position and secure the I/P harness to the vehicle.



34. Disconnect the engine module wiring harness connectors (1-3) from the underhood electrical center. Refer to Underhood Electrical Center or Junction Block Replacement in Wiring Systems.
35. Disconnect the wiring harness from the transmission control module (TCM). Refer to Torque Converter Replacement in Automatic Transmission - 5L40-E/5L50-E.



36. Remove the ground bolt and wire from the longitudinal rail.



37. Disconnect the engine harness electrical connector at the longitudinal rail.
38. Position and secure the ground wire, engine harness and TCM harness to the engine.




Important: Do NOT disconnect the brake pipes from the master cylinder.

39. Remove the master cylinder nuts.
40. Reposition and secure the master cylinder to the engine.
41. Relieve the fuel system pressure. Refer to Fuel Pressure Relief in Engine Controls - 2.8L (LP1).
42. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
43. Remove the muffler assembly. Refer to Exhaust System Replacement in Engine Exhaust.
44. Remove the propeller shaft. Refer to Propeller Shaft Replacement in Propeller Shaft.
45. Remove the air deflector. Refer to Front Air Deflector Replacement in Body Front End.

Important: DO NOT remove the water bottle.

46. Remove the washer bottle bracket. Refer to Windshield Washer Solvent Container Replacement in Wipers/Washer Systems.
47. Disconnect the radiator side air baffles from the radiator.
48. Disconnect the left front brake pipe retainer with the brake pipe from the longitudinal rail.
49. Remove the right front brake pipe from the brake pipe bundle retainer.
50. Disconnect the rear brake pipes (2 center pipes) from the brake modulator valve (BPVM). Refer to Brake Pressure Modulator Valve Replacement in Antilock Brake System.
51. Cap and/or plug the brake pipes and the BPMV in order to minimize brake fluid loss.
52. Remove the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
53. Remove the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement - Center in Steering Wheel and Column.



54. Remove the lower engine mount nuts. Refer to Engine Mount Replacement - Left Side and Engine Mount Replacement - Right Side .



55. Disconnect the transmission shift linkage from the transmission. Refer to Shift Control Linkage Replacement Automatic Transmission - 5L40-E/5L50-E.
56. Disconnect the low oil level sensor electrical connector.
57. Secure the low oil level sensor electrical connector and harness to the engine mount bracket.
58. Remove the headlamp leveling sensors. Refer to Headlamp Leveling Front Suspension Height Sensor Replacement in Lighting Systems.
59. Secure the shock modules to the lower control arms with a suitable strap in order to prevent damage to the front brake hoses.



60. Remove the right and left shock module upper mounting bolts. Refer to Shock Absorber and Spring Assembly Replacement in Front Suspension.
61. Raise the vehicle enough to place a suitable lift table under the engine, transmission, front frame and front suspension assembly.
62. Position a suitable powertrain and/or engine lift table below the frame, engine and transmission.
63. Raise the lift table and/or lower the vehicle to support the frame, engine and transmission.
64. Remove the transmission brace to underbody bolts. Refer to Transmission Support Replacement in Frame and Underbody.



65. Remove the front frame bolts (2).

Important: Ensure that all the hoses, wires, pipes and shock modules clear the vehicle during the removal process.

66. With the aid of an assistant, lower the table and/or raise the vehicle to remove the engine, transmission, front frame and front suspension assembly from the vehicle.



67. Disconnect the engine control module (ECM) upper (chassis side) electrical connector. Refer to Engine Control Module Replacement in Engine Controls - 2.8L (LP1).

Important: Do NOT remove the oxygen sensors.

68. Remove the catalytic converters with the oxygen sensors. Refer to Catalytic Converter Replacement - Left Side and Catalytic Converter Replacement - Right Side in Engine Exhaust.
69. Remove the thermostat housing with the heater pipes, heater hoses and surge tank outlet hose. Refer to Engine Coolant Thermostat Housing Removal .
70. Remove the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
71. Remove the flywheel bolts.



72. Remove the heated oxygen sensor (HO2S) connector bracket from the left cylinder head.
73. Remove the engine wiring harness and related components. Refer to Engine Wiring Harness Assembly Removal .
74. Disconnect the transmission oil cooler (TOC) pipes from the engine, radiator and the transmission. Refer to Transmission Fluid Cooler Hose/Pipe Replacement in Automatic Transmission - 5L40-E/5L50-E.
75. Disconnect the radiator hoses from the water outlet housing and the coolant inlet pipe. Refer to Radiator Inlet Hose Replacement in Engine Cooling.
76. Disconnect the power steering cooler hoses from the condenser radiator and fan module (CRFM). Refer to Power Steering Cooler Pipe/Hose Replacement in Power Steering System.
77. Cap and plug the power steering hoses and pipes in order to prevent fluid loss and contamination.
78. Remove the CRFM with the radiator hoses from the frame.
79. Install the EN 46114 to the engine. Refer to Engine Support Fixture .
80. Connect a floor crane to the engine lift brackets and raise the floor crane to partially support the engine.
81. Position a second powertrain lift table below the transmission.
82. Remove the transmission to engine bolts. Refer to Transmission Replacement in Automatic Transmission - 5L40-E/5L50-E.
83. Remove the transmission from the engine.
84. Remove the drive belts. Refer to Water Pump and Generator Belt Replacement and Air Conditioning Compressor and Power Steering Pump Belt Replacement .
85. Remove the generator and water pump drive belt tensioner. Refer to Drive Belt Tensioner Removal - Right Side .
86. Remove the A/C compressor and power steering drive belt tensioner. Refer to Drive Belt Tensioner Removal - Left Side .
87. Remove the idler pulley. Refer to Drive Belt Idler Pulley Removal .
88. Remove the generator and the generator bracket. Refer to Generator Removal .
89. Remove the air conditioning (A/C) compressor. Refer to Air Conditioning (A/C) Compressor Removal .
90. Remove the power steering pump. Refer to Power Steering Pump Removal .
91. Remove the power steering reservoir from the engine. Refer to Remote Power Steering Fluid Reservoir Replacement in Power Steering System.
92. Remove the oil level indicator. Refer to Oil Level Indicator and Tube Removal .
93. Remove the left exhaust manifold. Refer to Exhaust Manifold Removal - Left Side .
94. Remove the oil filter adapter. Refer to Oil Filter Adapter Removal .
95. Remove the right exhaust manifold. Refer to Exhaust Manifold Removal - Right Side .
96. Remove the crankshaft balancer. Refer to Crankshaft Balancer Removal .
97. Remove the flywheel. Refer to Engine Flywheel Removal .
98. Remove the intake manifold. Refer to Intake Manifold Removal .
99. Remove the water outlet. Refer to Water Outlet Removal .
100. Remove the block heater. Refer to Coolant Heater Replacement in Engine Cooling.
101. Remove the ECM with the ECM bracket. Refer to Engine Control Module Replacement in Engine Controls - 2.8L (LP1).
102. Use a floor crane in order to remove the engine from the frame.
103. Remove the engine mount brackets with the engine mounts. Refer to Engine Mount Bracket Replacement - Left Side and Engine Mount Bracket Replacement - Right Side .

1. Install the engine mount brackets with the engine mounts. Refer to Engine Mount Bracket Replacement - Left Side and Engine Mount Bracket Replacement - Right Side .
2. Use a floor crane in order to install the engine to the frame.
3. Install the ECM with the ECM bracket. Refer to Engine Control Module Replacement in Engine Controls - 2.8L (LP1).
4. Install the water outlet. Refer to Starter Installation .
5. Install the block heater. Refer to Coolant Heater Replacement in Engine Cooling.
6. Install the flywheel. Refer to Engine Flywheel Installation .
7. Install the intake manifold. Refer to Intake Manifold Installation .
8. Install the crankshaft balancer. Refer to Crankshaft Balancer Installation .
9. Install the right exhaust manifold. Refer to Exhaust Manifold Installation - Right Side .
10. Install the oil filter adapter. Refer to Oil Filter Adapter Installation .
11. Install the left exhaust manifold. Refer to Exhaust Manifold Installation - Left Side .
12. Install the oil level indicator. Refer to Oil Level Indicator and Tube Installation .
13. Install the generator and the generator bracket. Refer to Generator Installation .
14. Install the power steering pump. Refer to Power Steering Pump Installation .
15. Install the power steering reservoir to the engine. Refer to Remote Power Steering Fluid Reservoir Replacement in Power Steering System.
16. Install the A/C compressor. Refer to Air Conditioning (A/C) Compressor Installation .
17. Install the idler pulley. Refer to Drive Belt Idler Pulley Installation .
18. Install the A/C compressor and power steering drive belt tensioner. Refer to Drive Belt Tensioner Installation - Left Side .
19. Install the generator and water pump drive belt tensioner. Refer to Drive Belt Tensioner Installation - Right Side .
20. Install the drive belts. Refer to Water Pump and Generator Belt Replacement and Air Conditioning Compressor and Power Steering Pump Belt Replacement .
21. Install the transmission-to-engine and flywheel-to-torque convertor bolts. Refer to Transmission Replacement in Automatic Transmission - 5L40-E/5L50-E.
22. Install the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
23. Remove the EN 46114 from the engine. Refer to Engine Support Fixture .
24. Install the CRFM with the radiator hoses to the frame.
25. Connect the power steering cooler hoses to the CRFM. Refer to Power Steering Cooler Pipe/Hose Replacement in Power Steering System.
26. Connect the radiator hoses to the water outlet housing and the coolant inlet pipe. Refer to Radiator Inlet Hose Replacement in Engine Cooling.
27. Install the TOC pipes to the engine, radiator and the transmission. Refer to Transmission Fluid Cooler Hose/Pipe Replacement in Automatic Transmission - 5L40-E/5L50-E.
28. Install the engine wiring harness and related components. Refer to Engine Wiring Harness Assembly Installation .



29. Install the HO2S connector bracket to the left cylinder head.
30. Install the thermostat housing with the heater pipes, heater hoses and surge tank outlet hose. Refer to Engine Coolant Thermostat Housing Removal .
31. Install the catalytic converters with the oxygen sensors. Refer to Catalytic Converter Replacement - Left Side and Catalytic Converter Replacement - Right Side in Engine Exhaust.
32. Install the fuel lines to the fuel rail and the evaporative emission (EVAP) purge solenoid. Refer to Metal Collar Quick Connect Fitting Service in Engine Controls - 2.8L (LP1).



33. Connect the ECM upper (chassis side) electrical connector. Refer to Engine Control Module Replacement in Engine Controls - 2.8L (LP1).

Important: Ensure that all the hoses, wires, pipes and shock modules clear the vehicle during the installation process.

34. With the aid of an assistant, raise the table and/or lift the vehicle to install the engine, transmission, front frame and front suspension assembly to the vehicle.



35. Install the front frame bolts (2). Refer to Front Frame Replacement in Frame and Underbody.
36. Install the transmission support to underbody bolts. Refer to Transmission Support Replacement in Frame and Underbody.
37. Remove the powertrain lift/support table.



38. Install the right and left shock module upper mounting bolts. Refer to Shock Absorber and Spring Assembly Replacement in Front Suspension.
39. Secure the shock modules to the front frame with mechanics wire to avoid stretching the front brake hoses.
40. Install the headlamp leveling sensors. Refer to Headlamp Leveling Front Suspension Height Sensor Replacement in Lighting Systems.



41. Connect the transmission shift linkage to the transmission. Refer to Shift Control Linkage Replacement Automatic Transmission - 5L40-E/5L50-E.
42. Connect the low oil level sensor electrical connector.



43. Install the lower engine mount nuts. Refer to Engine Mount Replacement - Left Side and Engine Mount Replacement - Right Side .
44. Install the intermediate steering shaft . Refer to Intermediate Steering Shaft Replacement - Center in Steering Wheel and Column.
45. Install the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
46. Install the front brake pipes and retainers to the underbody.
47. Connect the rear brake pipes (2 center pipes) to the brake pressure modulator valve (BPVM). Refer to Brake Pressure Modulator Valve Replacement in Antilock Brake System .
48. Connect the radiator side air baffles to the radiator.
49. Install the washer bottle bracket. Refer to Windshield Washer Solvent Container Replacement in Wiper/Washer Systems.
50. Install the air deflector. Refer to Front Air Deflector Replacement in Body Front End.
51. Install the propeller shaft. Refer to Propeller Shaft Replacement in Propeller Shaft.
52. Install the muffler assembly. Refer to Exhaust System Replacement in Engine Exhaust.



53. Install the master cylinder. Refer to Master Cylinder Replacement in Hydraulic Brakes.



54. Connect the engine harness electrical connector at the longitudinal rail.



55. Install the ground wire and bolt to the longitudinal rail.

Tighten
Tighten the engine harness ground wire to longitudinal rail bolt to 10 N·m (89 lb in).

56. Connect the wiring harness to the TCM. Refer to Torque Converter Replacement in Automatic Transmission - 5L40-E/5L50-E.



57. Connect the engine module wiring harness connectors (1-3) to the underhood electrical center. Refer to Underhood Electrical Center or Junction Block Replacement in Wiring Systems.
58. Connect and lock the I/P electrical connector to the engine at the rear of the left (Bank 2) cylinder head.
59. Connect the mass air flow sensor electrical connector.
60. Connect the brake fluid level switch electrical connector from the master cylinder.



61. Connect the brake booster vacuum hose (1) to the brake booster (2).
62. Install the radiator support brackets. Refer to Radiator Support Bracket Replacement in Engine Cooling.



63. Connect the purge line (3) to the purge solenoid.
64. Connect the fuel pipe (2) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service in Engine Controls - 2.8L (LP1).
65. Connect the heater hoses to the heater core. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement in Heating, Ventilation and Air Conditioning.
66. Install the air inlet duct.
67. Position and secure the surge tank inlet (vent) hose to the vehicle.
68. Connect the surge tank inlet (vent) hose to the water outlet housing and the radiator. Refer to Radiator Surge Tank Outlet Hose/Pipe Replacement in Engine Cooling.
69. Connect the surge tank outlet hose to the surge tank. Refer to Radiator Surge Tank Inlet Hose/Pipe Replacement in Engine Cooling.
70. Connect the air conditioning pressure switch electrical connector and the liquid line to the evaporator. Refer to Liquid Line Replacement in Heating, Ventilation and Air Conditioning.
71. Connect the air conditioning suction hose to the evaporator and install the suction hose bracket to the shock tower. Refer to Suction Hose Replacement in Heating, Ventilation and Air Conditioning.



72. Install the air cleaner duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 2.8L (LP1).



73. Install the cooling fan wiring harnesses (1 and 4) to the fan shroud.
74. Install the cooling fan electrical connectors (2 and 3).
75. Install the wiper module. Refer to Windshield Wiper System Module Replacement .
76. Install the battery. Refer to Battery Replacement in Engine Electrical.
77. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .



78. Connect the battery positive cable to the battery and the underhood electrical center. Refer to Battery Positive Cable Replacement in Engine Electrical.
79. Connect the battery negative cable from the battery and the body. Refer to Battery Negative Cable Replacement in Engine Electrical.



80. Remove the J 42640 from the steering column.
81. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
82. Charge the air conditioning system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.
83. Bleed the brake rear circuits. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.