Engine - Installation

INSTALLATION

Special Tools:









Figure 1 - FLYWHEEL AND ADAPTER PLATE

NOTE: A new clamping ring must be used any time the flex plate or flywheel adapter is removed.

1. If removed, install the flywheel and adapter or flexplate. Tighten bolts to 137 Nm (100 ft. lbs).










2. Remove the cylinder head bolts (1 and 3) according to the diagram. Install special Tool (2). Tighten bolts to 105 Nm (77 ft. lbs.).
3. Lower the engine into the engine compartment and install the engine mount through bolts and nuts.
4. Tighten the mount through bolts and nuts to 129 Nm (95 ft. lbs).
5. Remove the chain with 2 hooks and the Engine Lifting Bracket (2).
6. Check the cylinder head bolt length and install into cylinder head.
7. Torque in 4 steps to:
- Step 1-Tighten to 70 Nm (52 ft. lbs.).
- Step 2-Back off 360°.
- Step 3-Tighten to 105 Nm (77 ft. lbs.).
- Step 4-Rotate 90°.

8. Replace injector O-ring and sealing washer on injectors No. 5, No. 6. Install injectors and tighten using the following steps:
- Step 1-Install the injector hold-down capscrews and tighten to 5 Nm (44 in. lbs.).
- Step 2-Loosen the injector hold-down capscrews.
- Step 3-Install the HPC connector tube and nut. Tighten nut to 15 Nm (133 in. lbs.).
- Step 4-Tighten the injector hold-down capscrews to 10 Nm (89 in. lbs.).
- Step 5-Tighten the HPC connector tube nut to 50 Nm (37 ft. lbs.).

9. Remove the front and rear engine lift bracket.





10. If fuel tube at No. 6 cylinder has been removed, tilt metal bracket (4) upward to install the No. 6 fuel tube finger tight.
11. Install the No. 5 and No. 6 high pressure fuel lines. Tighten fuel line fittings to 40 Nm (35 ft. lbs.).
12. Position the metal bracket (4) at the rear of cylinder head back and tighten bolts (3) to 43 Nm (32 ft. lbs.).





13. Install the pushrods, rocker arms (1), and pedestals (2) for cylinders No. 4, No. 5, and No. 6. Tighten the mounting bolts to 36 Nm (27 ft. lbs).
14. Reset the valve lash on cylinders No. 4, No. 5, and No. 6. for the intake valve at 0.254 mm (0.010 in.) and exhaust valve at 0.66 mm (0.026 in.). Tighten adjusting nuts to 24 Nm (18 ft. lbs.).
15. Install the EGR cooler EGR Cooler - Installation





16. Install the cylinder head cover/injector wiring gasket (2).
17. Install the injector harness nuts to injectors (1). Tighten to 1.25 Nm (11 in. lbs.).
18. Connect the injector wiring harness connectors to injector connections on cylinder head cover carrier gasket (3).





19. Install the cylinder head cover (1) Cylinder Head Cover(s) - Installation





20. Install the transmission to engine bolts.
- Automatic transmission, tighten bolts to 41 Nm (30 ft. lbs.).
- Manual transmission, tighten bolts to 45 Nm (33 ft. lbs.).

21. Install the transmission collar (1). Tighten to 77 Nm (57 ft. lbs.).





22. Connect the fuel supply and return lines from the fuel filter housing.
23. Connect the heater core supply and return hoses.
24. Using a new V-clamp, install the exhaust pipe to the turbocharger elbow (1). Tighten V-clamp to 11 Nm (97 in. lbs.).
25. Connect left side, engine block to frame ground wire.
26. Connect the engine block heater harness connector.
27. Connect the generator harness wires.
28. Install the battery negative cables to the engine block on the driver and passenger side.
29. Connect the intake heater connector.
30. Install the starter cable to the left battery and power distribution center.
31. Connect engine wiring harness connector from Totally Integrated Power Module (TIPM).






NOTE: Illustration shown with lower radiator hose removed for clarity.

32. Remove the tape or plugs from the opened refrigerant line fittings and compressor ports.
33. Lubricate new O-ring seals with clean refrigerant oil and install them and a new gasket onto the refrigerant line fittings. Use only the specified O-ring seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
34. Connect the A/C suction line (3) and A/C discharge line (4) to the A/C compressor (2).
35. Install the A/C suction and discharge line assembly to the compressor. Tighten the nuts to 23 Nm (17 ft. lbs.).





36. Install the power steering pump Power Steering Pump - Installation.
37. Install the power steering reservoir Reservoir, Power Steering Pump - Installation.
38. Install the serpentine drive beltSerpentine Accessory Drive Belt - Installation.
39. Install the fan and fan shroud Electric Radiator Fan - Installation.
40. Install the radiator and connect the upper and lower radiator hoses.





41. Install the radiator closure panel Radiator Closure Panel - Installation.
42. Connect the transmission harness connector.
43. Install the left ground strap.
44. Install the Barring Tool (1).
45. Using the Barring Tool (1), rotate the engine and install the torque converter bolts. Tighten bolts to 88 Nm (65 ft. lbs.).
a. On manual transmission models, install the dual mass flywheel bolts. Tighten bolts to 88 Nm (65 ft. lbs.).
46. Remove the Barring Tool (1).





47. Install the bell housing access plate. Tighten bolts to 10 Nm (89 in. lbs.).





48. Change the oil filter and fill with recommended new engine oil.
49. Evacuate and recharge A/C systemRefrigerant System Charge.
50. Fill the cooling system with coolantService and Repair.
51. Install the air cleaner body Air Cleaner Body - Installation
52. Connect both negative and positive battery cables.
53. Start the engine and inspect for engine oil, coolant, and fuel leaks.





54. Position the hood and connect hood support struts.
55. Install the engine cover. Tighten bolts (1) to 10 Nm (89 in. lbs.).