Installation

Installation Procedure




1. Install an engine lift chain to the engine lift brackets and attach to an engine lift device.
2. Remove the engine from the engine stand.
3. Ensure the torque converter is fully engaged with the transmission oil pump (M30 only).
4. Position the engine mounts to the engine.
5. Install the engine mount bolts until snug, following the installation sequence.
The engine lift device may have to be raised or lowered slightly to install these bolts.

Caution: Refer to Fastener Caution (Fastener Caution).

6. Tighten the bolts using the installation sequence to 50 Nm (37 lb ft).





Note: Ensure clearance is maintained between the engine and the following:

* The A/C compressor
* The A/C hoses
* The engine mounts
* The engine wiring harness
* The fuel hose/pipes
* The heater outlet hose/pipe
* The power steering pump
* The transmission input shaft (manual only)
* The transmission oil cooler pipes (automatic only)

7. Carefully lower the engine into the engine compartment, aligning the engine dowels with the transmission.





Note: Ensure the torque converter turns freely while tightening the transmission mounting bolts (automatic only).

8. Align the engine dowels (1) with the transmission.
9. Loosely install the 2 transmission mounting bolts (2).
Ensure the dowels (1) are fully engaged into the transmission.
10. Remove the jack from under the vehicle.
11. Lower the engine fully on to the engine mounts.
12. Remove the engine lift chain from the engine lift brackets.
13. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).




14. Tighten the 2 transmission mounting bolts (2) previously installed to 50 Nm (37 lb ft).





Note:
* Ensure the studded mounting bolts (2) are located in the correct position.
* The heater pipe (1) must be secured with the 2 upper mounting bolts.

15. Install the remaining transmission mounting bolts and tighten to 50 Nm (37 lb ft).
16. Align the torque converter to flexplate/flywheel orientation marks made during the removal procedure (automatic only).
17. Repeat the following steps for all 3 torque converter bolts (automatic only):

1. Rotate the harmonic balancer center bolt clockwise ONLY, in order to access the torque converter bolt holes in the flexplate/flywheel through the service slot.
2. To aid in alignment of the torque converter to the flexplate/flywheel, install all 3 torque converter bolts before fully tightening. Tighten the torque converter bolts to 60 Nm (44 lb ft).




18. Install the inspection plug (3) to the transmission (1) (automatic only).




19. Install the bolt (2) securing the transmission oil cooler pipe bracket to the right side of the engine oil pan rail (automatic only).
Tighten the transmission oil cooler pipe bracket bolt to 20 Nm (15 lb ft).
20. Install the exhaust seal. Refer to Exhaust Seal Replacement (LH8) (Service and Repair)Exhaust Seal Replacement (LLR) (Service and Repair).




21. Install the service slot plug.
22. Install the crossmember. Refer to Crossmember Replacement (Crossmember Replacement).




23. Position the differential carrier assembly to the frame.
24. Install the differential carrier assembly bushing to frame bolts and tighten to 152 Nm (112 lb ft).
25. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement (Front Propeller Shaft Replacement).




26. Install the fuel line clips to the brackets on the transmission (automatic only).
Tighten the fuel hose/pipe bracket nuts to 20 Nm (15 lb ft).




27. Install the fuel line clips to the brackets on the transmission (manual only).
Tighten the fuel hose/pipe bracket nuts to 20 Nm (15 lb ft).




28. Connect the engine wiring harness retainer (5) to the engine oil pan rail.
29. Install the 3 bolts securing the engine wiring ground leads (2) to the engine block Tighten the bolts to 20 Nm (15 lb ft).
30. Lower the vehicle to chest level in order to access the components through the wheelhouse.
31. Connect the engine wiring harness connector (3) to the CKP sensor (1).




32. Install the A/C compressor and bolts to 50 Nm (37 lb ft), if equipped.




33. Install the A/C evaporator line to the compressor and install the bolt at the A/C compressor, if equipped.
Tighten the bolt to 16 Nm (12 lb ft).




34. Install the A/C condenser line to the compressor and install the bolt at the A/C compressor, if equipped.
Tighten the bolts to 16 Nm (12 lb ft).




35. Position the J 38185 (2) to the clamp (1) in order to connect the heater outlet hose to the heater outlet hose fitting (3).




36. Connect the engine wiring harness retainers (1, 2) to the A/C compressor and the engine oil pan rail.




37. Connect the engine wiring harness connector (3) to the number 2 KS (1).
38. Connect the coolant heater cord to the coolant heater, if equipped.




39. Connect the engine wiring harness connector to the EVAP canister purge solenoid valve.




40. Install the bolt (5) securing the battery negative cable ground terminal (4) to the engine block and tighten the bolt to 35 Nm (26 lb ft).




41. Connect the battery positive cable (2) to the starter and install the starter terminal nut (1) and tighten the nut to 9 Nm (80 lb in).
42. Connect the lead (4) to the starter solenoid and install the starter solenoid "S" terminal nut (3).
Tighten the starter solenoid "S" terminal nut to 3.5 Nm (31 lb in).




43. Secure the following wiring harness retainers to the engine wiring harness bracket:

* The battery cable
* The engine (4, 6)
* The MAP sensor (5)

44. Lower the vehicle.




45. Install the left engine mount-to-frame bracket bolt and tighten to 85 Nm (63 lb ft).




46. Connect the MAP sensor wiring harness retainer (4) to the intake manifold.
47. Install the MAP sensor. Refer to Manifold Absolute Pressure Sensor Replacement (Service and Repair).
48. Install the oil level indicator and tube. Refer to Oil Level Indicator Tube Replacement (Service and Repair).
49. Connect the EVAP pipe at the purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
50. Connect the fuel feed pipe to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).




51. Connect the engine wiring harness retainer to the engine wiring harness bracket.




52. Install the right engine mount-to-frame bracket bolt and tighten to 85 Nm (63 lb ft).




53. Position the power steering pump to the power steering pump bracket.
54. Install the power steering pump mounting bolts and tighten to 25 Nm (18 lb ft).




55. Connect the inlet heater hose quick connect (1) to the heater core (2).




56. Remove the J 44220 from the cylinder head.




57. Position the AIR pipe cover and NEW gasket to the cylinder head.
58. Install the AIR pipe cover studs and tighten to 25 Nm (18 lb ft).
59. Install the transmission filler tube, if equipped. Refer to Transmission Fluid Filler Tube and Seal Replacement (3.7L) (Service and Repair)Transmission Fluid Filler Tube and Seal Replacement (5.3L) (Service and Repair).




60. Position the A/C compressor evaporator hose bracket to the cylinder head and install the bolt. Tighten the bolt to 9 Nm (80 lb in).




61. Engage the engine wiring harness conduit to the camshaft cover.




62. Connect the engine wiring harness connector to the Intake CMP sensor.




63. Connect the engine wiring harness retainer (3) to the camshaft cover (4).
64. Connect the engine wiring harness connector (2) to the throttle body (1).




65. Connect the engine wiring harness connectors to the following components:

* The ECT sensor (1)
* The fuel injector harness (2)
* The ignition coils (4)
* The HO2S (5)




66. Connect the engine wiring harness retainer (2) to the camshaft cover (3).
67. Connect the engine wiring harness connectors to the following components:

* The exhaust CMP sensor (5)
* The exhaust camshaft actuator (6)




68. Connect the engine wiring harness retainers (1) to the power steering pump (2).
69. Connect the engine wiring harness connectors to the following components:

* The electric motor actuator connector (4WD only)
* The oil pressure switch




70. Connect the engine wiring harness retainers to the wheelhouse.
71. Connect the 2 engine wiring harness connectors to the PCM.
72. Install the washer solvent container/coolant recovery reservoir mounting bolts. Refer to Windshield Washer Solvent Container Replacement (Windshield Washer Solvent Container Replacement).
73. Install the radiator. Refer to Radiator Replacement (Gasoline) (Radiator Replacement (Gasoline)).




74. Position the J 38185 to the clamp (3) in order to connect the radiator inlet hose (2) to the water outlet housing (4).
75. Install the generator. Refer to Generator Replacement (LLR) (Service and Repair)Generator Replacement (LH8) (Service and Repair).
76. Install the air cleaner resonator and outlet duct. Refer to Air Cleaner Resonator and Outlet Duct Replacement (Air Cleaner Resonator and Outlet Duct Replacement).
77. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
78. Install the cooling fan. Refer to Fan Replacement (LLR) (Fan Replacement)Fan Replacement (LH9) (Fan Replacement).
79. Install the outlet radiator hose. Refer to Radiator Outlet Hose Replacement (LLR) (Radiator Outlet Hose Replacement)Radiator Outlet Hose Replacement (LH9) (Radiator Outlet Hose Replacement).
80. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (Service and Repair)Cooling System Draining and Filling (Vac-N-Fill) (Service and Repair).
81. Install the battery box. Refer to Battery Box Replacement (LH8,LLR) (Battery Box Replacement).
82. Install the hood. Refer to Hood Replacement (Service and Repair).
83. Fill the engine oil, if previously drained. Refer to Engine Oil and Oil Filter Replacement (Service and Repair).
84. Charge the A/C system. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging).

Engine Final Test and Inspection

Complete the following procedure after the engine is installed in the vehicle:

1. With the ignition OFF or disconnected, crank the engine several times. Listen for any unusual noises or evidence that any parts are binding.
2. Start the engine and listen for abnormal conditions.
3. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
4. Run the engine at approximately 1,000 RPM until the engine reaches normal operating temperature.
5. While the engine continues to idle raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
6. Inspect for oil, coolant, transmission fluid, and exhaust leaks while the engine is idling.
7. Lower the vehicle.
8. Perform the CKP variation learn procedure. Refer to Crankshaft Position System Variation Learn (Programming and Relearning).
9. Perform a final inspection for the proper engine oil, transmission fluid and coolant levels.
10. Road test the vehicle.