Installation

Engine









WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

WARNING: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.

1. Using the Heavy Duty Floor Crane and the Engine Lifting Bracket, install the engine into the vehicle.





2. Install the LH engine insulator nut.
- Tighten to 63 Nm (46 lb-ft).






3. Install the RH engine insulator nut.
- Tighten to 63 Nm (46 lb-ft).






4. Install the ground wire and the bolt to the rear of the LH cylinder head.
- Tighten to 10 Nm (89 lb-in).






5. Install the clutch disc and pressure plate.

6. Install a new engine oil filter in the following sequence.
1. Lubricate the oil filter gasket with clean engine oil and tighten until the seal makes contact.

2. Using an oil filter strap wrench, tighten the filter an additional 270 degrees.






7. Connect the 2 Electronic Power Assist Steering (EPAS) electrical connectors and attach the wiring harness retainer.





8. Install the A/C compressor and the 3 stud bolts.
- Tighten to 25 Nm (18 lb-ft).






9. Position the Supercharger (SC) drive onto the A/C compressor and attach the 2 wiring harness retainers onto the A/C compressor stud bolts.





10. Connect the wiring harness retainer to the back of the A/C compressor.





11. Connect the A/C compressor electrical connector.





12. Attach the wire harness retainer to the A/C compressor stud bolt.





13. Connect the Crankshaft Position (CKP) sensor electrical connector.





14. Position the lower radiator hose assembly into the vehicle.
- Connect the lower radiator hose to the radiator.






15. Connect the coolant hose to the oil cooler.





16. Rotate the SC (Supercharger) drive belt tensioner clockwise and install the drive belt onto the SC (Supercharger) drive pulley.





17. Position the Battery Junction Box (BJB) terminal and install the nut.
- Tighten to 10 Nm (89 lb-in).






18. Install the PDB (Power Distribution Box) cover.

19. Connect the 16-pin electrical connector and attach the wiring retainers.





20. Connect the 16-pin electrical connector and attach the 2 wiring retainers.





21. Connect the 2 PCM electrical connectors.





22. Attach the 2 wiring harness pin-type retainers.





23. Attach the pin-type wire harness retainer to the cowl.





24. Position the ground cables and install the 2 bolts.
- Tighten to 10 Nm (89 lb-in).






25. Connect the 2 heater hoses to the coolant tube assembly at the rear of the engine.





26. Connect the Evaporative Emission (EVAP) tube quick connect coupling and the brake booster vacuum supply tube to the Throttle Body (TB) spacer.





27. Connect the fuel supply tube.





28. Connect the coolant hose to the coolant pump.





29. Connect the coolant hose to the thermostat housing.





30. Connect the coolant hose to the coolant tube assembly (above the generator).





31. Connect the coolant hose to the Charge Air Cooler (CAC).





32. NOTE: RH bolt shown, LH similar.
Install the cooling fan assembly and the 2 bolts.

- Tighten to 9 Nm (80 lb-in).






33. Position the charge air cooler hose and install the bolt.
- Tighten to 8 Nm (71 lb-in).






34. Connect the cooling fan electrical connector.





35. Connect the upper radiator hose from the thermostat housing.





36. Install the SC (Supercharger) coolant degas bottle.

37. Install the engine coolant degas bottle.

38. Install the brake booster.

39. Install the battery tray and battery.

40. Install the Air Cleaner (ACL) and ACL (Air Cleaner) outlet pipe.

41. Install the battery and tray.

42. NOTE: Use the hood hinge location index marks made during removal to aid in hood installation.
Install the hood and the 4 bolts.

- Tighten to 12 Nm (106 lb-in).






43. Attach the 2 windshield washer hose retainers and connect the 2 windshield washer hose C-Lock Couplers.





44. Install the 2 windshield washer hose retainers and the 8 hood insulation pin-type retainers (2 shown).





45. Fill the engine with clean engine oil.

46. Fill and bleed the engine cooling system. For additional information, refer to Cooling System &/or Engine Block Heater.

47. Fill and bleed the SC (Supercharger) cooling system. For additional information, refer to Cooling System.

48. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.