Part 1
Engine Replacement
Special Tools
EN 46114 Engine Lifting Brackets
Removal Procedure
1. Turn the ignition key to the LOCK position.
Warning: Refer to Battery Disconnect Warning (Battery Disconnect Warning).
2. Disconnect the battery ground cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
3. Remove the engine covers. Refer to Engine Cover Replacement (Service and Repair).
4. Remove the radiator air intake baffle. Refer to Cooling Fan and Shroud Replacement (Service and Repair).
5. Recover the air conditioning (A/C) refrigerant. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging).
6. Remove the air intake duct. Refer to Air Cleaner Inlet Duct Replacement (Air Cleaner Inlet Duct Replacement).
7. Depressurize the fuel system. Refer to Fuel Pressure Relief (Fuel Pressure Relief).
8. Drain the cooling system. Refer to Cooling System Draining and Filling (3.6 L) (Service and Repair)Cooling System Draining and Filling (6.0 L) (Service and Repair).
9. Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (3.6L) (Service and Repair)Radiator Outlet Hose Replacement (6.0L) (Service and Repair).
10. Compress the coolant bleed hose retaining clamp (4) at the outlet housing (1) end and slide 50 mm (2 in) along the coolant bleed hose (3).
11. Remove the coolant bleed hose (3) from the outlet housing (1).
Note: Twist and pull the coolant recovery hose (2) to remove from the outlet housing (1).
12. Disconnect the coolant recovery hose (2) from the outlet housing (1).
Note: Plug or cap the hoses and inlets when separating the cooling system components, this prevents dirt and other contaminants from entering the cooling system.
13. Plug or cap the cooling system hoses and inlets
Warning: Refer to Safety Glasses Warning (Safety Glasses Warning).
Note: The inlet and outlet heater hoses (1) are retained to the heater pipes (2) by quick connect fittings. Disconnect the heater hose (1) quick connect fittings by releasing the retaining clips (3) with a suitable tool.
14. Disconnect the heater hose (1) from the heater pipe (2) in two places.
15. Compress the vacuum hose retaining clamp (2) at the intake manifold vacuum port (3) and slide 50 mm (2 in) back along the vacuum hose (1).
16. Disconnect the vacuum hose (1) from the intake manifold vacuum port (3) and secure away from the engine.
17. Remove the engine coolant heater cord if fitted. Refer to Coolant Heater Cord Replacement (3.6L) (Coolant Heater Cord Replacement)Coolant Heater Cord Replacement (6.0L) (Coolant Heater Cord Replacement).
18. Rotate the engine control module (ECM) electrical connector levers (1) up to the unlocked position.
19. Disconnect ECM electrical connectors (2) from the ECM.
20. Disconnect the 56 pin engine wiring harness to main wiring harness electrical connector (1).
21. Disconnect the two pin engine wiring harness to main wiring harness electrical connector (2).
22. Remove the under hood body electrical centre (BEC) cover (1).
23. Remove the positive cable protective cover (3).
24. Remove the positive cable to under hood BEC plate retaining bolt (5).
25. Disconnect the positive cable (2) from the upper under hood BEC plate (4).
26. Remove the under hood BEC upper plate to lower plate retaining bolts (2).
27. Raise the upper under hood BEC plate (1) from the lower under hood BEC plate (3).
28. Detach the protector (1) from the base of the under hood BEC connector (2).
Note: Use a suitable tool to depress the connector locking tang (2), then pull the body harness connector (1) upward and the engine connector (3) downward to separate the body harness connector (1) from the engine connector (3).
29. Separate the body harness connector (1) from the engine connector (3).
30. Reposition and secure the engine wiring harness and connector (3) on the engine.
31. Remove the vehicle body ground cable to cylinder head retaining bolt (3)
32. Disconnect the vehicle body ground cable (1) from the cylinder head (2).
33. Remove the remote positive battery post cover (1) from the remote positive battery post.
34. Remove the remote positive battery post to wiring harness retaining bolt (1).
35. Remove the wiring harness (2) from the remote positive battery post.
36. Disconnect the A/C pressure transducer electrical connector (1).
37. Disconnect the A/C compressor electrical connector (1).
38. Remove the suction/discharge line pad to A/C compressor retaining nut (1).
39. Disconnect the A/C suction/discharge line pad (1) from the A/C compressor (3).
Note: Plug or cap the A/C suction/discharge pipe ends and the compressor ports immediately to prevent contamination and absorption of moisture from the atmosphere.
40. Plug or cap the A/C suction/discharge pipe (1) ends and the compressor (3) ports.
Note: The A/C sealing O-rings (2) are a single use component and will not reseal. Install NEW A/C sealing O-rings (2) whenever the A/C suction/discharge line pad (1) is removed from the A/C compressor (3).
41. Remove and discard the A/C suction/discharge pipe sealing O-rings (2).
Discard the O-rings (2).
Remove the A/C suction pipe pad to A/C suction pipe retaining nut (1).
42. Disconnect the upper A/C suction pipe (1) from the lower A/C suction tube (3).
Note: Plug or cap the A/C suction pipe ends (1 and 3) immediately to prevent contamination and absorption of moisture from the atmosphere.
43. Plug or cap the A/C suction pipe ends.
Note: The A/C suction pipe sealing O-ring (2) is a single use component and will not reseal. Install a NEW A/C suction pipe sealing O-ring (2) whenever the upper A/C suction pipe (1) is removed from the lower A/C suction pipe (3).
44. Remove and discard the A/C suction pipe sealing O-ring (2).
Discard the O-ring (2).
45. Reposition and retain the A/C suction/discharge pipes away from the engine.
46. Disconnect the fuel feed hose (1) from the fuel feed pipe (2). Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service) or Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
Note: Plug or cap the fuel feed pipe (2) and fuel feed hose (1) ends to prevent fuel leaks and/or contamination.
47. Plug or cap the fuel feed pipe (2) and fuel feed hose (1) ends.
48. Disconnect the evaporative emission (EVAP) purge line (4) from the purge solenoid (3). Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service) or Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
49. Plug or cap the (EVAP) purge line (4) and the purge solenoid (3) ends.
Note: The flexible hoses are not serviced separately. Therefore if the hose's require replacement, then the hose and radiator to hose cooler hose assembly must be fitted.
Note: When removal is complete plug hose openings with a clean lint free cloth to prevent foreign matter entry.
50. Place a suitable container beneath the radiator and engine.
51. Disconnect the transmission cooler line (2) from the flexible hose (1) at the quick connect fitting using tool. AU525.
* Open release tool AU525 then close and clip around the hose to be disconnected.
* While holding the flexible hose (1) push the hose inwards with one hand, then pull back to separate from the steel hose piping (2).
* Repeat for the second fitting.
52. Reposition and secure the flexible hoses (1) away from the engine and subframe.
Note: It is necessary to secure the radiator and condenser assembly (2) to the front end assembly (3) as the radiator and condenser assembly is supported to the subframe.
Note: Thread zip tie A around the front end assembly and zip tie B through the radiator and condenser mount (1). Insert zip tie A into the retainer of zip tie B and insert zip tie B into the retainer of zip tie A.
53. Secure radiator and condenser assembly (2) to the front end assembly (3) with large zip ties or equivalent.
Warning: Refer to Safety Glasses Warning (Safety Glasses Warning).
Danger: 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.
54. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
55. Remove the front air deflector. Refer to Front Air Deflector Replacement (Service and Repair).
56. Remove the Engine Splash Shield. Refer to Engine Splash Shield Replacement (Service and Repair).
57. Disconnect the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (3.6L) (Service and Repair)Radiator Inlet Hose Replacement (6.0L) (Service and Repair).
58. Place a suitable container under the power steering cooler.
Note: The power steering cooler (3) must be plugged to prevent the entry of foreign particles into the power steering system.
59. Release the power steering gear outlet hose spring clamp (2) and disconnect the power steering gear outlet hose (1) from the power steering cooler (3).
Plug the power steering cooler (3) and power steering gear outlet hose (1).
Note: The power steering cooler (3) must be plugged to prevent the entry of foreign particles into the power steering system.
60. Release the power steering reservoir inlet hose spring clamp (1) and disconnect the power steering reservoir inlet hose (2) from the power steering cooler (3).
Plug the power steering cooler (3) and power steering reservoir inlet hose (2).
61. Disconnect the oil level/temperature sensor electrical connector (1).
62. Remove the exhaust system. Refer to Exhaust System Replacement (V8 - For Access) (Exhaust System Replacement (For Access))Exhaust System Replacement (V8 - Complete) (Exhaust System Replacement (Complete))Exhaust System Replacement (V6 - For Access) (Exhaust System Replacement (For Access))Exhaust System Replacement (V6 - Complete) (Exhaust System Replacement (Complete)) or Exhaust System Replacement (V8 - For Access) (Exhaust System Replacement (For Access))Exhaust System Replacement (V8 - Complete) (Exhaust System Replacement (Complete))Exhaust System Replacement (V6 - For Access) (Exhaust System Replacement (For Access))Exhaust System Replacement (V6 - Complete) (Exhaust System Replacement (Complete)).
63. Remove the centre exhaust heat shield. Refer to Exhaust Heat Shield Replacement - Center (Exhaust Heat Shield Replacement - Center).
64. Remove the propeller shaft. Refer to Propeller Shaft Replacement (Propeller Shaft Replacement).
65. Remove the shift selector linkage rod to shift selector shaft retaining nut (3).
66. Remove the shift selector linkage rod (1) from the shift selector shaft (2).
67. Remove the starter motor. Refer to Starter Replacement (3.6L) (Service and Repair)Starter Replacement (6.0L) (Service and Repair).
68. Partially lower the vehicle.
69. Remove the front wheels. Refer to Tire and Wheel Removal and Installation (Service and Repair).
70. Detach the front brake hose (1) from the strut mounted brake hose retaining bracket (2). Repeat for opposite side.
Note: Bolts with micro-encapsulated thread sealant must be discarded after removal.
Note: Make sure all the bolt holes are thoroughly cleaned and all micro-encapsulated thread sealant is removed.
71. Remove the front brake caliper anchor plate to knuckle retaining bolts (1). Repeat for opposite side.
* Discard the bolts.
* Clean the bolt holes.
Important: DO NOT disconnect the hydraulic brake flexible hose from the brake caliper otherwise complete bleeding of the braking system will be necessary.
72. Remove the front brake caliper (2) from the front steering knuckle (3). Repeat for opposite side.
Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak.
73. Support the front brake caliper (1) with heavy mechanic's wire, or equivalent (2). Repeat for opposite side.
74. Install two wheel nuts (4) to retain the front brake disc (3) to the hub (5). Repeat for opposite side.
75. Disconnect the front wheel speed sensor jumper harness electrical connector (1) and secure away from the subframe and suspension components. Repeat for opposite side.
Note: The front wheels of the vehicle must be maintained in the straight ahead position and the steering column must be in the LOCK position before disconnecting the steering column or intermediate shaft. If these procedures are not followed incorrect alignment of some components during installation will result and damage to the SIR coil assembly will occur.
Note: Observing the orientation of the intermediate steering shaft (1) with reference to the pinion shaft (3) will minimize the potential of incorrect steering column assembly alignment.
76. Mark the intermediate steering shaft (1) in relation to the pinion shaft (3).
77. Remove the intermediate steering shaft to pinion shaft retaining bolt (2).
Important: Bolts with micro-encapsulated thread sealant must be discarded after removal.
Important: Make sure the bolt hole is thoroughly cleaned and all micro-encapsulated thread sealant is removed.
78. Disconnect the intermediate shaft (2) from the pinion shaft (3).
* Discard the bolt.
* Clean the bolt hole.
79. Lower the vehicle.
Note: The strut assembly (1) must be secured to the subframe (3) to prevent damage to the front wheelhouse liner, fenders and suspension components.
80. Retain the front strut assembly (1) to the front subframe (3) using heavy mechanics wire or equivalent (2). Repeat for opposite side.
81. Remove the stud dust cover (1) from the strut assembly to front wheelhouse retaining nut (2).
Note: The strut assembly (4) must be supported from underneath before the strut assembly to front wheelhouse retaining nut (2) is removed.
82. Remove the strut assembly to front wheelhouse retaining nut (2) while holding the strut piston shaft (4) with a suitable tool.
Discard the nut.
83. Remove the strut assembly to front wheelhouse retaining plate (3).
84. Position a suitable powertrain and/or engine lift table below the frame, engine and transmission.
85. Raise the lift table and/or lower the vehicle to support the frame, engine and transmission.
86. Remove the transmission support to body retaining bolts (1).
87. Remove the subframe reinforcement plate to subframe retaining bolts (2).
88. Remove the subframe reinforcement plate (3) from the subframe (1).
89. Remove the subframe to body rear retaining bolts (1).
Note: Only right side depicted in graphic, left side similar.
90. Remove the subframe to body front retaining bolt (1). Repeat for opposite side.
Note: Only right side depicted in graphic, left side similar.
91. Remove the subframe to body retaining bolt (1). Repeat for opposite side.
Note: Make sure that all the hoses, wires, pipes and front struts clear the vehicle during the removal process.
92. With the aid of an assistant, lower the table and/or raise the vehicle to remove the engine, transmission, front suspension and subframe assembly from the vehicle.
93. Remove the engine and transmission wiring harness and related components. Refer to Engine Wiring Harness Assembly Removal.
94. Remove the transmission cooler line clamp to alternator mounting bracket retaining nut (1).
95. Remove the transmission cooler line clamp (3) and transmission cooler lines (2) from the alternator mounting bracket (4).