Tools Required

1. Install J 42640 to the steering column.
2. Disconnect the positive and negative battery cables from the battery. Refer to Battery Negative Cable Disconnection and Connection and to Battery Positive Cable Replacement in Engine Electrical.
3. Remove the cross vehicle brace. Refer to Cross Vehicle Brace Replacement in Body Front End.
4. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .



5. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 4.6L (LH2).
6. Disconnect the surge tank inlet hose and position the hose to the engine.



7. Evacuate the air conditioning system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.
8. Disconnect the air conditioning suction hose fitting at the top of the left shock tower. Refer to Suction Hose Replacement in Heating, Ventilation and Air Conditioning.
9. Remove the suction hose from the retaining feature (1). Position the line to the engine.
10. Disconnect the air conditioning liquid line from the condenser. Refer to Liquid Line Replacement in Heating, Ventilation and Air Conditioning.
11. Remove the air conditioning liquid line from the retaining feature on the fan shroud.



12. Disconnect the brake booster vacuum line (1) from the brake booster (2). Position the brake booster line to the engine.
13. Disconnect the electrical connector on the brake fluid level switch from the master cylinder.



14. Remove the master cylinder mounting nuts.
15. Position the master cylinder to the engine. Hold the master cylinder in position by using mechanics wire. Do not disconnect the brake lines from the master cylinder.
16. Relieve the fuel system pressure. Refer to Fuel Pressure Relief in Engine Controls - 4.6L (LH2).



17. Remove the fuel line retainer (1) from the vehicle. The retainer is located on the bracket attached to the heater lines on the front of the dash.
18. Disconnect the engine wiring harness connector C102 at the front of the dash. Refer to Harness Routing Views in Wiring Systems.
19. Disconnect the underhood fuse block connector C5 located between the right shock tower and the cam cover. Refer to Harness Routing Views in Wiring Systems.
20. Remove the underhood electrical center cover.



21. Remove the negative battery cable (2) bolt from the right shock tower. Remove the cable retainer from the stud on the right shock tower and position the cable to the engine.



22. Remove the positive battery cable nut from inside the underhood electrical center. Remove the cable from the electrical center and position the cable to the engine.
23. Disconnect the chassis electrical connector at the top of the right shock tower. Position the wire to the engine.
24. Disconnect the electrical connector for the transmission control module and position the wiring harness to the engine. Refer to Transmission Control Module Replacement in Automatic Transmission - 5L40-E/5L50-E.
25. Disconnect the engine wiring harness C5 connector from the inside of the underhood electrical center. Refer to Underhood Electrical Center or Junction Block Replacement in Wiring Systems.
26. Disconnect the electrical connector C113 at the right frame rail. Refer to Underhood Electrical Center or Junction Block Replacement in Wiring Systems.
27. Remove the engine cooling fans. Refer to the appropriate procedure in Engine Cooling:

•	Fan Replacement

•	Engine Cooling Fan Replacement

28. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
29. Remove the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.



30. Remove the right and left wheelhouse splash shields. Refer to Engine Splash Shield Replacement in Body Front End.
31. Remove the right and left front fascia extensions. Refer to Front Bumper Fascia Extension Replacement in Bumpers.
32. Working through the right wheelhouse, remove the brace that secures the windshield washer reservoir to front frame.
33. Place a suitable drain pan under the vehicle.
34. Working through the left wheelhouse, disconnect the transmission oil cooler lines located near the air conditioning compressor.



35. Remove the bolt (3) that secures the center intermediate shaft to the lower intermediate shaft.
36. Separate the 2 shafts.
37. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.



38. Remove the bolt securing the power steering cooler lines to the radiator assembly.
39. Lower the vehicle.
40. Remove the radiator, condenser, and transmission oil cooler as an assembly. Refer to Radiator Replacement in Engine Cooling and to Condenser Replacement in Heating, Ventilation and Air Conditioning.
41. Raise the vehicle.
42. Remove the bolts from the mounting bracket on the power steering oil cooler. Refer to Power Steering Fluid Cooler Replacement in Power Steering System. Position the oil cooler to the engine. Secure the cooler to the engine with mechanics wire.



43. Remove the transfer case, if equipped. Refer to Transfer Case Assembly Replacement in Transfer Case - BW 4476.
44. Remove the transmission assembly. Refer to Transmission Replacement in Automatic Transmission - 5L40-E/5L50-E.
45. Remove the brake bundle clips from the right and left frame rails. Do not remove the clips from the brake lines.
46. Disconnect the fuel line from the fuel filter. Refer to Fuel Hose/Pipes Replacement - Chassis in Engine Controls - 4.6L (LH2).
47. Disconnect the evaporative emission (EVAP) hose connection at the rear of the fuel filter. Refer to Evaporative Emission Hoses/Pipes Replacement - Chassis/Canister in Engine Controls - 4.6L (LH2).
48. Disconnect the rear brake lines from the bracket above the rear axle assembly. Refer to Brake Pipe Replacement in Hydraulic Brakes.
49. Remove the fuel and brake line bundle retainers from the frame rail along the length of the vehicle. Do not remove the retainers from the lines. Refer to Fuel Hose/Pipes Replacement - Chassis in Engine Controls - 4.6L (LH2).
50. Remove the fuel filter bracket to provide a removal path for the fuel and brake line bundle assembly.
51. Remove the fuel and brake line bundle bracket from the right side wheelhouse.
52. Lower the vehicle.
53. Disconnect the outlet hose from the heater outlet pipe at the right frame rail. Position the hose to the engine.
54. Disconnect the inlet hose from the water housing and position the hose to the vehicle.
55. If the vehicle is equipped with Magnaride, disconnect the electrical connectors from the top of the right and left shock modules.
56. Remove the upper mounting bolts from the right and left shock module.
57. Secure the shock modules to the front frame with mechanics wire to avoid stretching the front brake hoses.
58. Raise the vehicle enough to place a suitable lift table under the engine, front frame, and front suspension assembly.

Caution: To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.

59. Support the rear of the vehicle with suitable jack stands.
60. Raise the lift table and/or lower the vehicle to preload the weight of the engine, front frame, and front suspension assembly.
61. Remove the front frame bolts.
62. With the aid of an assistant, lower the table and/or raise the vehicle to remove the engine, front frame, fuel/brake bundle and front suspension assembly from the vehicle.
63. Ensure that all the hoses, wires, pipes and shock modules clear the vehicle during the removal process.



64. Install J 28467-86 to the left cylinder head. Refer to Engine Support Fixture .



65. Install J 28467-87 to the right cylinder head. Refer to Engine Support Fixture .
66. Using a suitable engine lift, remove the engine from the front frame assembly.

1. Install the engine to the front frame.
2. Ensure that all the hoses, wires, pipes and shock modules are positioned out of the way to avoid contact during engine installation.
3. With the aid of an assistant, raise the table and/or lower the vehicle to install the engine, front frame, fuel/brake bundle and front suspension.

Notice: Refer to Fastener Notice in the Preface section.

4. Install the frame bolts.

Tighten
Tighten the frame bolts to 191 N·m (141 lb ft).

5. Install the right and left upper shock modules bolts.

Tighten
Tighten the bolts to 112 N·m (83 lb ft).

6. If the vehicle is equipped with Magnaride, connect the shock module electrical connectors.
7. Connect the heater inlet hose to the water housing.
8. Connect the heater outlet hose to the outlet pipe.
9. Raise the vehicle.
10. Install the fuel and brake line bundle bracket to the right side wheelhouse.

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

11. Install the fuel filter bracket bolt.

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

12. Install the fuel and brake line to the bundle brackets, the length of the vehicle.
13. Install the rear brake line to the bracket bolt above the rear axle assembly.

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

14. Connect the EVAP hose to the rear of the fuel filter.
15. Connect the fuel line to the fuel filter.
16. Install the brake lines to the bundle clips on the right and left frame rails.
17. Install the transmission assembly. Refer to Transmission Replacement in Automatic Transmission - 5L40-E/5L50-E.
18. Install the transfer case, if equipped. Refer to Transfer Case Assembly Replacement in Transfer Case - BW 4476.
19. Install the powers steering oil cooler to the mounting bracket. Refer to Power Steering Fluid Cooler Replacement in Power Steering System.
20. Lower the vehicle.
21. Install the radiator, condenser and transmission oil cooler as an assembly. Refer to Radiator Replacement in Engine Cooling and to Condenser Replacement in Heating, Ventilation and Air Conditioning.
22. Raise the vehicle.
23. Install the bolt that secures the power steering to the radiator.

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




24. Connect the center intermediate shaft to the lower intermediate shaft.

Tighten
Tighten the bolt to 30 N·m (23 lb ft).

25. Install the bolt (3) that secures 2 shafts.
26. Working through the left wheelhouse, connect the transmission oil cooler lines near the air conditioning compressor.
27. Working through the right hand wheelhouse, install the bolt which secures the washer fluid reservoir to the front frame brace.

Tighten
Tighten the bolt to 6 N·m (53 lb in).

28. Install the right and left front fascia extensions. Refer to Front Bumper Fascia Extension Replacement in Bumpers.
29. Install the right and left wheelhouse splash shields. Refer to Engine Splash Shield Replacement in Body Front End.
30. Install the right and left front tire assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
31. Lower the vehicle.
32. Install the cooling fan. Refer to the appropriate procedure in Engine Cooling:

•	Fan Replacement

•	Engine Cooling Fan Replacement

33. Connect the electrical connector C113 at the right hand frame rail. Refer to Underhood Electrical Center or Junction Block Replacement in Wiring Systems.
34. Connect the electrical connector C5 to the underhood bussed electrical center. Refer to Underhood Electrical Center or Junction Block Replacement in Wiring Systems.
35. Connect the transmission control module. Refer to Transmission Control Module Replacement in Automatic Transmission - 5L40-E/5L50-E
36. Connect the chassis electrical connector located at the top of the right hand shock tower.
37. Install the positive battery cable to the underhood bussed electrical center.

Tighten
Tighten the battery cable nut to 15 N·m (11 lb ft).

38. Install the negative battery cable retainer and bolt to the right hand shock tower.

Tighten
Tighten the retainer bolt to 36 N·m (27 lb ft).

39. Install the underhood electrical center cover.
40. Connect the underhood fuse block connector C5.
41. Connect the front of the dash electrical connector C102. Refer to Harness Routing Views in Wiring Systems.
42. Install the fuel line retainer located on the bracket attached to the heater lines on the front of the dash.
43. Install the brake master cylinder.

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

44. Connect the brake fluid level switch.
45. Connect the brake booster vacuum line to the brake booster.
46. Install the air conditioning liquid line to the condenser. Refer to Liquid Line Replacement in Heating, Ventilation, and Air Conditioning.



47. Install the air conditioning suction hose located at the top of the left hand shock tower. Refer to Suction Hose Replacement in Heating, Ventilation, and Air Conditioning.
48. Install the air conditioning liquid and suction lines to the retaining feature (1) on the fan shroud.
49. Connect the coolant surge tank hose to the radiator.



50. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 4.6L (LH2).
51. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
52. Install the cross vehicle brace. Refer to Cross Vehicle Brace Replacement in Body Front End.
53. Install the positive battery cable. Refer to Battery Positive Cable Replacement in Engine Electrical.
54. Install the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
55. Remove J 42640 .
56. Fill the engine with engine oil. Refer to Engine Oil and Oil Filter Replacement .
57. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
58. Recharge the air conditioning system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation, and Air Conditioning.
59. Bleed the brake system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brake System.