Engine Replacement 4.8L, 5.3L, and 6.0L Engines

Tools Required

1. Open the hood.
2. Place the fender covers over both fenders.
3. Raise the hood to the service position and perform the following:

3.1.	Remove the hood hinge bolts (1).

3.2.	Raise the hood until vertical.

3.3.	Install the hood hinge bolts until snug in the service position (2).

4. Remove the air conditioning (A/C) compressor. Refer to Air Conditioning Compressor Replacement .
5. Remove the radiator support. Refer to Radiator Support Replacement .
6. Remove the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement .



7. Open the hose clamp and remove the radiator inlet hose from the water pump.



8. Open the hose clamp and remove the radiator outlet hose from the water pump.
9. Remove the heater hoses. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement .



10. Disconnect the following electrical connectors:

•	The evaporative emission (EVAP) canister purge solenoid (1)

•	The generator (3)

11. Remove the harness bracket nut (2) in order to remove the engine harness from the intake manifold.



12. Reposition the vent inlet hose clamp at the throttle body.
13. Remove the radiator vent inlet hose from the throttle body.



14. Remove the generator cable from the generator and perform the following procedure:

14.1.

Slide the boot down revealing the terminal stud.

14.2.

Remove the generator cable nut from the terminal stud.

14.3.

Remove the generator cable.




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



16. Disconnect the following electrical connectors:

•	The main coil harness (4)

•	The fuel injectors (3)

•	The electronic throttle control (ETC) (2)




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



18. Remove the harness ground bolt.
19. Reposition the harness ground and negative battery cable from the block.
20. Disconnect the following electrical connectors:

•	The engine coolant temperature (ECT) sensor (5)

•	The electronic variable orifice switch




21. Remove the harness ground bolt at the right rear of the engine block.
22. Reposition the harness ground and auxiliary negative battery cable, if equipped, from the block.
23. Remove the harness ground bolt at the left rear of the engine block.
24. Reposition the harness ground and engine ground strap from the block.
25. Disconnect the following electrical connectors:

•	The oil pressure sensor (1)

•	The camshaft position (CMP) sensor (3)

26. Unclip all of the engine harness clips from the engine.



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



28. Remove the EVAP purge solenoid vent tube. Perform the following procedure:

28.1.

Remove the EVAP tube end from the solenoid (1).

28.2.

Remove the EVAP tube end from the vapor pipe (2).

29. Disconnect the fuel pipes. Refer to Metal Collar Quick Connect Fitting Service .
30. Raise the vehicle.



31. Disconnect the following electrical connectors:

•	The crankshaft position (CKP) sensor (1)

•	The engine oil sensor (3)

•	The coolant heater, if equipped




32. Remove the battery cable channel bolt.
33. Slide the channel pin out of the oil pan tab.
34. Gather all branches of the engine wiring harness and reposition off to the side.
35. Lower the vehicle.



36. Remove the rear power steering to engine block bolt.
37. Remove the generator bracket bolts.
38. Position the bracket aside.



39. Remove the vacuum brake booster hose.
40. Remove the ignition coils, as required, for the proper fit of the J 41798 before lifting the engine. Refer to Ignition Coil Replacement .

Notice: Refer to Fastener Notice in the Preface section.




41. Install the J 41798 to the cylinder heads.

Tighten

•	Tighten the M8 bolts to 25 N·m (18 lb ft).

•	Tighten the M10 bolts to 50 N·m (37 lb ft).




42. Remove the left and right engine mount to engine mount bracket bolts.
43. Raise the vehicle.



44. Remove the engine sight shield bolts and shield.



45. Remove the oil pan skid plate bolts and plate, if equipped.
46. Drain the engine oil.
47. Remove the starter motor. Refer to Starter Motor Replacement .
48. Remove the catalytic converter. Refer to Catalytic Converter Replacement .



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



50. Remove the torque converter bolts, if equipped.



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



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



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



54. If equipped with a 4L80-E transmission, remove the transmission converter cover bolts.



55. Remove the automatic transmission bolt/studs, if equipped.
56. Separate the engine from the automatic transmission, if equipped. Install the J 21366 to the transmission in order to hold the torque converter.



57. Using J 42371 , remove the clutch line form the concentric slave cylinder.



58. Remove the manual transmission stud on the right side of the transmission, if equipped.



59. Remove the manual transmission bolt/studs, if equipped.
60. Separate the manual transmission from the engine, if equipped.



61. Mark the flywheel and a clutch pressure plate lug for installation alignment.
62. Remove the clutch pressure plate bolts, if equipped.
63. Remove the clutch pressure plate and disc, if equipped.
64. Lower the vehicle.
65. Install an engine hoist to the J 41798 .
66. 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.

67. Remove the engine.
68. Install the engine to an engine stand.
69. Remove the engine hoist.



70. Remove the J 41798 from the engine.

Notice: Refer to Fastener Notice in the Preface section.

1. Install the J 41798 to the engine.

Tighten

•	Tighten the M8 bolts to 25 N·m (18 lb ft).

•	Tighten the M10 bolts to 50 N·m (37 lb ft).

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

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. Refer to Ignition Coil Replacement .
12. Raise the vehicle.



13. Install the disc and clutch pressure plate and bolts until snug, if equipped.
14. Using J 5824-A , align the clutch disc splines with the pilot bearing.
15. Align the marks made during removal.



16. Tighten the clutch pressure plate bolts in the sequence shown, evenly over 3 increments with the fourth increment to the final specification.

Tighten
Tighten the bolts to 70 N·m (52 lb ft).




17. Install the clutch line to the concentric slave cylinder.



18. Install the manual transmission bolt/studs, if equipped.



19. Install the manual transmission stud on the right side of the transmission, if equipped.

Tighten
Tighten the bolt/studs to 50 N·m (37 lb ft).




20. Remove the J 21366 from the transmission.
21. Install the automatic transmission, if equipped.



22. If equipped with a 4L80-E transmission, install the transmission converter cover bolts.



23. If equipped with a 4L60-E transmission, install the transmission bolt and stud on the right side.

Tighten
Tighten the bolts/studs to 50 N·m (37 lb ft).




24. Install the automatic transmission oil level indicator tube, if equipped.



25. Install the automatic transmission oil level indicator tube nut, if equipped.

Tighten
Tighten to nut to 18 N·m (13 lb ft).




26. Install the torque converter bolts, if equipped.

Tighten

•	If equipped with a 4L60-E transmission, tighten the bolts to 63 N·m (47 lb ft)

•	If equipped with a 4L80-E transmission, tighten the bolts to 60 N·m (44 lb ft).




27. Install the positive cable clip and bolt.

Tighten
Tighten the bolt to 9 N·m (80 lb in).

28. Install the catalytic converter. Refer to Catalytic Converter Replacement .
29. Install the starter motor. Refer to Starter Motor Replacement .



30. Install the oil pan skid plate and bolts, if equipped.

Tighten
Tighten the bolts to 20 N·m (15 lb ft).




31. Install the engine shield and bolts.

Tighten
Tighten the bolts to 20 N·m (15 lb ft).

32. Lower the vehicle.



33. Install the vacuum brake booster hose.



34. Position the generator bracket to the front of the engine.
35. Install the generator bracket bolts until snug.
36. Install the rear power steering pump to engine block bolt until snug.

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

37. Route the engine wiring harness to the lower engine area.
38. Raise the vehicle.



39. Slide the channel pin into the oil pan tab.
40. Install the battery cable channel bolt.

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




41. Connect the following electrical connectors:

•	The CKP sensor (1)

•	The engine oil level sensor (3)

•	The coolant heater, if equipped

42. Lower the vehicle.
43. Connect the fuel pipes. Refer to Metal Collar Quick Connect Fitting Service .



44. Install the EVAP purge solenoid vent tube to the solenoid (1).
45. Install the EVAP tube to the vapor pipe (2).



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



48. Connect the following electrical connectors:

•	The oil pressure sensor (1)

•	The CMP sensor (3)

49. Position the harness ground and the engine ground strap to the block.
50. Install the harness ground bolt at the left rear of the engine block.
51. Position the harness ground and auxiliary negative battery cable, if equipped, to the block.
52. Install the harness ground bolt at the right rear of the engine block.

Tighten
Tighten the bolts to 16 N·m (12 lb ft).




53. Connect the following electrical connectors:

•	The ECT sensor (5)

•	The electronic variable orifice switch

54. Position the harness ground and negative battery cable to the block.
55. Install the harness ground bolt.

Tighten
Tighten the bolt to 25 N·m (18 lb ft).




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



57. Connect the following electrical connectors:

•	The main coil harness (4)

•	The fuel injectors (3)

•	The ETC (2)




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



59. Install the generator cable to the generator. Perform the following procedure:

59.1.

Install the generator cable.

59.2.

Install the generator cable nut to the terminal stud.

Tighten
Tighten the nut to 9 N·m (80 lb in).

59.3.

Slide the boot over the terminal stud.




60. Install the radiator vent inlet hose to the throttle body.
61. Position the vent inlet hose clamp at the throttle body.



62. Install the engine wiring harness bracket and nut (2).

Tighten
Tighten the nut to 5 N·m (44 lb in).

63. Connect the following electrical connectors:

•	The EVAP canister purge solenoid (1)

•	The generator (3)

64. Install the heater hoses. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement .



65. Open the hose clamp and install the radiator outlet hose to the water pump.



66. Open the hose clamp and install the radiator inlet hose to the water pump.
67. Install the radiator support. Refer to Radiator Support Replacement .
68. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement .



69. Remove the hood hinge bolts from the service position (2).
70. Lower the hood to the normal position.
71. Install the hood hinge bolts.

Tighten
Tighten the bolts to 25 N·m (18 lb ft).

72. Remove the fender covers.
73. Fill the crankcase with the proper quantity and grade of engine oil. Refer to Approximate Fluid Capacities or Fluid and Lubricant Recommendations .
74. Bleed the hydraulic clutch, if equipped. Refer to Hydraulic Clutch Bleeding .
75. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn .

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

76. Test the vehicle using the following procedure:

76.1.

Disable the ignition system.

76.2.

Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.

76.3.

Enable the ignition system.

76.4.

Start the engine and listen for unusual noises.

76.5.

Check the vehicle oil pressure gage or light and confirm that the engine has acceptable oil pressure.

76.6.

Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.

76.7.

Listen for sticking lifters and other unusual noises.

76.8.

Inspect for fuel, oil, and/or coolant leaks while the engine is running.

76.9.

Perform a final inspection for the proper engine oil an coolant levels.

77. Install the engine shield. Refer to Upper Intake Manifold Sight Shield Replacement .
78. Close the hood.

Engine Replacement 5.3L Engine w/RPO HP2

Tools Required

1. Open the hood.
2. Place the fender covers over both fenders.
3. Raise the hood to the service position. Perform the following procedure:

3.1.	Remove the hood hinge bolts (1).

3.2.	Raise the hood until vertical.

3.3.	Install the hood hinge bolts until snug in the service position (2).

4. Disconnect the energy storage box (ESB). Refer to Hybrid Battery Service Disconnect/Connect in Engine Electrical.
5. Remove the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement .
6. Remove the radiator support. Refer to Radiator Support Replacement in Body Front End.



7. Remove the A/C drive belt. Refer to Air Conditioning Compressor Belt Replacement .
8. Remove the discharge hose bolt and hose from the compressor.
9. Remove the suction hose bolt and hose from the compressor.
10. Discard the sealing washers. Cap the compressor and line openings.
11. Disconnect the compressor electrical connections.
12. Remove the A/C compressor bolts. The lower right bolt (3) will stay with the compressor due to a lack of clearance.
13. Remove the A/C compressor (2).



14. Open the hose clamp and remove the radiator inlet hose from the water pump.



15. Open the hose clamp and remove the radiator outlet hose from the water pump.
16. Remove the heater hoses. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement in Heating, Ventilation and Air Conditioning.
17. Remove the auxiliary heater water pump. Refer to Auxiliary Water Pump Replacement in Engine Cooling.



18. Disconnect the evaporative emission (EVAP) canister purge solenoid (1).
19. Remove the harness bracket nut (2) in order to remove the engine harness from the intake manifold.



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



21. Remove the connector position assurance (CPA) retainer (1) from the main coil harness connector.
22. Disconnect the main coil harness (4) and fuel injector (2) electrical connectors on the left side.
23. Remove the harness clips (3, 5) from the fuel rail.



24. Remove the CPA retainer (1) from the main coil harness connector.
25. Disengage the CPA retainer on the electronic throttle control (ETC).
26. Disconnect the main coil harness (4), fuel injectors (3), and ETC (2) electrical connectors on the right side.
27. Remove the harness clips (1) from the fuel rail.



28. Remove the engine wiring harness ground bolt (4).
29. Reposition the harness ground (2) and negative battery cable (3) from the block.
30. Disconnect the engine coolant temperature (ECT) sensor (5) electrical connector.



31. Remove the harness ground bolt at the right rear of the engine block.
32. Reposition the harness ground (2) and auxiliary negative battery cable, if equipped, from the block.
33. Remove the harness ground bolt at the left rear of the engine block.
34. Reposition the harness ground, and engine ground strap from the block.
35. Disconnect the following electrical connectors:

•	The oil pressure sensor (1)

•	The camshaft position (CMP) sensor (3)

36. Unclip any missed engine harness clips from the engine.



37. Disconnect the EVAP purge solenoid vent tube from the solenoid (1) and vapor pipe (2).
38. Remove the EVAP tube.
39. Disconnect the fuel feed line. Refer to Metal Collar Quick Connect Fitting Service in Engine Controls - 4.8L, 5.3L, and 6.0L.
40. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



41. Disconnect the following electrical connectors from the engine:

•	The crankshaft position (CKP) sensor (1)

•	The engine oil level sensor (3)

•	The coolant heater, if equipped




42. Remove the battery cable channel bolt.
43. Slide the channel pin out of the oil pan tab.
44. Reposition the lower engine wiring harness off to the side.
45. Lower the vehicle.
46. Reposition the upper portion of the engine wiring harness off to the side.



47. Reposition the vent inlet hose clamp at the throttle body.
48. Remove the radiator vent inlet hose from the throttle body.



49. Remove the 3-phase cable bracket cover bolt (1).



50. Remove the starter/generator control module (SGCM) cover bolts and cover.
51. Remove the 3-phase cable nuts.
52. Remove the 3-phase cable from the SGCM studs.
53. Tie the cable out of the way.



54. Disconnect the engine harness electrical connector (3) from the power steering pump.



55. Remove the power steering pump harness 42-volt connector (5) from the wheelhouse panel.
56. Disconnect the power steering pump harness 42-volt electrical connectors (3, 5).



57. Remove the power steering pump harness bolt (3).
58. Remove the power steering pump harness clip (2) from the bracket.



59. Remove the power steering pump harness clip (1) from the bracket.
60. Remove the ground bolt (3).
61. Disconnect the power steering pump harness electrical connector (4) from the power steering pump.
62. Remove the power steering pump harness from the vehicle.



63. Remove the battery cable clip bolt (1).
64. Remove the battery cable junction block bracket bolts (2) from the power steering pump bracket.



65. Remove the power steering pump bolts (2).
66. Reposition the power steering pump (1) with the lines attached, off to the side.



67. Remove the power steering pump bracket bolts (1, 2) and bracket (3).



68. Remove the vacuum brake booster hose.
69. Remove the ignition coils, as required, for the proper fit of the J 41798 . Refer to Ignition Coil Replacement in Engine Controls - 4.8L, 5.3L, and 6.0L.

Notice: Refer to Fastener Notice in the Preface section.




70. Install the J 41798 to the cylinder heads.

Tighten

•	Tighten the M8 bolts to 25 N·m (18 lb ft).

•	Tighten the M10 bolts to 50 N·m (37 lb ft).




71. Remove the left and right engine mount to engine mount bracket bolts.
72. Raise the vehicle.



73. Remove the engine shield bolts and shield, if equipped.



74. Remove the oil pan skid plate bolts and plate, if equipped.
75. Drain the engine oil.
76. Remove the catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.



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



78. Remove the passenger side closeout cover bolt and cover.




Important: It is highly recommended to use a 3/8 inch, 6-point shallow thin wall socket and a wobble extension to loosen the torque converter bolts, and a 8 mm ball end hex key to remove the bolts, in order to prevent possibly stripping the bolts.

79. Remove the torque converter bolts.



80. Install J 46093 to the engine block.

The flange of J 46093 should locate into a hole in the flexplate. Use 2 M10 1.5 x 40 mm bolts for proper tool operation.

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




81. Remove the transmission oil level indicator tube bolt.



82. Remove the transmission oil level indicator tube from the transmission.



83. Remove the transmission studs (1) and bolts (2).



84. Remove the transmission nuts.
85. Install an engine hoist to the J 41798 .
86. Install a floor jack under the transmission bellhousing 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.

87. Separate the engine from the transmission. Install the J 21366 to the transmission in order to hold the torque converter.
88. Position or remove the transmission fill tube while removing the engine.
89. Remove the engine from the vehicle.
90. Once the engine is out of the vehicle, set the engine down.



91. Remove the stator studs.
92. Remove the stator.



93. Remove the flexplate bolts and flexplate.



94. Remove the rotor.
95. Install the engine onto an engine stand.
96. Remove the engine hoist.



97. Remove the J 41798 from the engine.

1. Install the J 41798 to the cylinder heads.

Tighten

•	Tighten the M8 bolts to 25 N·m (18 lb ft).

•	Tighten the M10 bolts to 50 N·m (37 lb ft).

2. Install an engine hoist to the J 41798 .
3. Remove the engine from the engine stand.
4. Set the engine down.



5. Install the rotor.



6. Install the flexplate and bolts.

Tighten
Tighten the bolts to 100 N·m (74 lb ft).




7. Install the stator.
8. Install the stator studs.

Tighten
Tighten the studs to 16 N·m (12 lb ft).

9. Install the engine to the vehicle.
10. Remove the J 21366 from the transmission.
11. Position or install the transmission fill tube while installing the engine.



12. Install the left and right engine mount to engine mount bracket bolts.

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

13. Install the upper transmission stud until snug.
14. Remove the floor jack from under the transmission bellhousing.
15. Remove the engine hoist.



16. Remove the J 41798 from the engine.
17. Install the ignition coils, as required. Refer to Ignition Coil Replacement in Engine Controls - 4.8L, 5.3L, and 6.0L.
18. Raise the vehicle.



19. Install the transmission nuts.

Tighten
Tighten the nuts to 12 N·m (106 lb in).




20. Install the transmission studs (1) and bolts (2).

Tighten
Tighten the studs/bolts to 50 N·m (37 lb ft).




21. Install the transmission oil level indicator tube to the transmission.



22. Install the transmission oil level indicator tube bolt.

Tighten
Tighten the bolt to 18 N·m (13 lb ft).




23. Remove the J 46093 from the engine block.




Important: It is highly recommended to use a 8 mm ball end hex key to install and hand tighten the torque converter bolts. Then use a 3/8 inch, 6-point shallow thin wall socket and a wobble extension to torque the torque converter bolts in order to prevent possibly stripping the bolts.

24. Install the torque converter bolts.

Tighten
Tighten the bolts to 63 N·m (46 lb ft).




25. Install the passenger side closeout cover and bolt.

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




26. Install the positive battery cable clip and bolt.

Tighten
Tighten the bolt to 9 N·m (80 lb in).

27. Install the catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.



28. Install the oil pan skid plate and bolts, if equipped.

Tighten
Tighten the bolts to 20 N·m (15 lb ft).




29. Install the engine shield and bolts, if equipped.

Tighten
Tighten the bolts to 20 N·m (15 lb ft).

30. Lower the vehicle.



31. Install the vacuum brake booster hose.



32. Install the power steering pump bracket (3) and bolts (1, 2).

Tighten
Tighten the bolts to 25 N·m (18 lb ft).




33. Position the power steering pump (1) with the lines attached to the bracket.
34. Install the power steering pump bolts (2).

Tighten
Tighten the bolts to 25 N·m (18 lb ft).




35. Install the battery cable junction block bracket bolts (2) to the power steering pump bracket.

Tighten
Tighten the bolts to 9 N·m (80 lb in).

36. Install the battery cable clip bolt (1).

Tighten
Tighten the bolt to 9 N·m (80 lb in).




37. Install the power steering pump harness to the vehicle.
38. Connect the power steering pump harness electrical connector (4) to the power steering pump.
39. Install the ground bolt (3).

Tighten
Tighten the bolt to 25 N·m (18 lb ft).

40. Install the power steering pump harness clip (1) to the bracket.



41. Install the power steering pump harness clip (2) to the bracket.
42. Install the power steering pump harness bolt (3).

Tighten
Tighten the bolt to 25 N·m (18 lb ft).




43. Connect the power steering pump harness 42-volt electrical connectors (3, 5).
44. Install the power steering pump harness 42-volt connector (5) to the wheelhouse panel.



45. Connect the engine harness electrical connector (3) to the power steering pump.



46. Position the cable.
47. Install the 3-phase cable to the SGCM studs.
48. Install the 3-phase cable nuts.

Tighten
Tighten the nuts to 9 N·m (80 lb in).

49. Install the SGCM cover and bolts.

Tighten
Tighten the bolts to 9 N·m (80 lb in).




50. Install the 3-phase cable bracket cover bolt (1).

Tighten
Tighten the bolt to 9 N·m (80 lb in).




51. Install the radiator vent inlet hose to the throttle body.
52. Position the vent inlet hose clamp at the throttle body.



53. Position the upper portion of the engine wiring harness.
54. Raise the vehicle.
55. Position the lower engine wiring harness.
56. Slide the channel pin into the oil pan tab.
57. Install the battery cable channel bolt.

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




58. Connect the following electrical connectors to the engine:

•	The CKP sensor (1)

•	The engine oil level sensor (3)

•	The coolant heater, if equipped

59. Lower the vehicle.



60. Connect the fuel feed line. Refer to Metal Collar Quick Connect Fitting Service in Engine Controls - 4.8L, 5.3L, and 6.0L.
61. Install the EVAP tube.
62. Connect the EVAP purge solenoid vent tube to the solenoid (1) and vapor pipe (2).



63. Connect the following electrical connectors:

•	The oil pressure sensor (1)

•	The CMP sensor (3)

64. Position the harness ground and engine ground strap to the block.
65. Install the harness ground bolt at the left rear of the engine block.

Tighten
Tighten the bolt to 16 N·m (12 lb ft).

66. Position the harness ground (2) and auxiliary negative battery cable, if equipped, to the block.
67. Install the harness ground bolt at the right rear of the engine block.

Tighten
Tighten the bolt to 16 N·m (12 lb ft).




68. Connect the ECT sensor (5) electrical connector.
69. Position the harness ground (2) and negative battery cable (3) to the block.
70. Install the engine wiring harness ground bolt (4).

Tighten
Tighten the bolt to 25 N·m (18 lb ft).




71. Install the harness clips (1) to the fuel rail.
72. Connect the main coil harness (4), fuel injectors (3), and ETC (2) electrical connectors on the right side.
73. Engage the CPA retainer on the ETC.
74. Install the CPA retainer (1) to the main coil harness connector.



75. Install the harness clips (3, 5) to the fuel rail.
76. Connect the main coil harness (4) and fuel injector (2) electrical connectors on the left side.
77. Install the CPA retainer (1) to the main coil harness connector.



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



79. Install the harness bracket nut (2).

Tighten
Tighten the nut to 5 N·m (44 lb in).

80. Connect the EVAP canister purge solenoid (1).
81. Install the auxiliary heater water pump. Refer to Auxiliary Water Pump Replacement in Engine Cooling.
82. Install the heater hoses. Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement in Heating, Ventilation and Air Conditioning.



83. Install the radiator outlet hose to the water pump and close the hose clamp.



84. Install the radiator inlet hose to the water pump and close the hose clamp.



85. Install the A/C compressor (2).
86. Install the A/C compressor bolts.

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

87. Connect the compressor electrical connections.
88. Remove the caps from the compressor and line openings. Install NEW sealing washers.
89. Install the suction hose and bolt to the compressor.

Tighten
Tighten the bolt to 16 N·m (12 lb ft).

90. Install the discharge hose and bolt to the compressor.

Tighten
Tighten the bolt to 16 N·m (12 lb ft).

91. Install the A/C drive belt. Refer to Air Conditioning Compressor Belt Replacement .
92. Install the radiator support. Refer to Radiator Support Replacement in Body Front End.
93. Connect the ESB. Refer to Hybrid Battery Service Disconnect/Connect in Engine Electrical.



94. Remove the hood hinge bolts from the service position.
95. Lower the hood to the normal position.
96. Install the hood hinge bolts.

Tighten
Tighten the bolt to 25 N·m (18 lb ft).

97. Remove the fender covers.
98. Fill the crankcase with the proper quantity and grade of engine oil. Refer to Approximate Fluid Capacities or Fluid and Lubricant Recommendations in Maintenance and Lubrication.
99. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn in Engine Controls - 4.8L, 5.3L, and 6.0L.
100. Test the vehicle using the following procedure:

100.1.

Disable the ignition system.

100.2.

Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.

100.3.

Enable the ignition system.

100.4.

Start the engine and listen for unusual noises.

100.5.

Check the vehicle oil pressure gage or light and confirm that the engine has acceptable oil pressure.

100.6.

Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.

100.7.

Listen for sticking lifters and other unusual noises.

100.8.

Inspect for fuel, oil, and/or coolant leaks while the engine is running.

100.9.

Perform a final inspection for the proper engine oil and coolant levels.

101. Install the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement .
102. Close the hood.