Installation

Engine Replacement

Special Tools
* EN 46114 Engine Lift Brackets
* J 42640 Steering Column Anti-Rotation Pin


Installation Procedure

1. Install the engine mount brackets with the engine mounts. Refer to Engine Mount Bracket Replacement - Left Side (Engine Mount Bracket Replacement - Left Side) and to Engine Mount Bracket Replacement - Right Side (AWD) (Engine Mount Bracket Replacement - Right Side)Engine Mount Bracket Replacement - Right Side (RWD) (Engine Mount Bracket Replacement - Right Side).
2. Use a floor crane in order to install the engine to the frame.
3. Install the ECM with the ECM bracket. Refer to Engine Control Module Replacement (Service and Repair).
4. Install the water outlet. Refer to Water Outlet Installation (138. Water Outlet Installation).
5. Install the block heater. Refer to Coolant Heater Replacement (LH2, KO5) (Coolant Heater Replacement (K05))Coolant Heater Replacement (LY7, KO5, LLT) (Coolant Heater Replacement (K05)).
6. Install the flywheel. Refer to Engine Flywheel Installation (131. Engine Flywheel Installation).
7. Install the intake manifold. Refer to Intake Manifold Installation (LLT) (130. Intake Manifold Installation).
8. Install the crankshaft balancer. Refer to Crankshaft Balancer Installation (132. Crankshaft Balancer Installation).
9. Install the right exhaust manifold. Refer to Exhaust Manifold Installation - Right Side (136. Exhaust Manifold Installation - Right Side).
10. Install the oil filter adapter. Refer to Oil Filter Adapter Installation (133. Oil Filter Adapter Installation).
11. Install the left exhaust manifold. Refer to Exhaust Manifold Installation - Left Side (134. Exhaust Manifold Installation - Left Side).
12. Install the oil level indicator. Refer to Oil Level Indicator and Tube Installation (135. Oil Level Indicator and Tube Installation).
13. Install the generator and the generator bracket. Refer to Starter Replacement (LH2) (Service and Repair)Starter Replacement (LLT) (Service and Repair) and Generator Bracket Replacement (LH2) (Generator Bracket Replacement)Generator Bracket Replacement (LLT) (Generator Bracket Replacement).
14. Install the power steering pump. Refer to Power Steering Pump Replacement (V6) (Power Steering Pump Replacement)Power Steering Pump Replacement (LH2) (Power Steering Pump Replacement).
15. Install the power steering reservoir to the engine. Refer to Power Steering Fluid Reservoir Replacement (V6) (Service and Repair)Power Steering Fluid Reservoir Replacement (LH2) (Service and Repair).
16. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement (LH2) (Removal and Replacement)Air Conditioning Compressor Replacement (LLT) (Removal and Replacement).
17. Install the A/C compressor and power steering drive belt tensioner. Refer to Drive Belt Tensioner Installation - Left Side (139. Drive Belt Tensioner Installation - Left Side).
18. Install the generator and water pump drive belt tensioner. Refer to Drive Belt Tensioner Installation - Right Side (140. Drive Belt Tensioner Installation - Right Side).
19. Install the drive belts. Refer to Water Pump and Generator Belt Replacement (Water Pump and Generator Belt Replacement) and to Air Conditioning Compressor and Power Steering Pump Belt Replacement (Air Conditioning Compressor and Power Steering Pump Belt Replacement).
20. Install the bolts that secure the transmission to the engine and the flywheel to the torque convertor.
21. Install the starter motor. Refer to Starter Replacement (LH2) (Service and Repair)Starter Replacement (LLT) (Service and Repair).
22. Remove EN 46114 from the engine. Refer to Engine Support Fixture (Engine Support Fixture).
23. Install the CRFM with the radiator hoses to the frame.
24. Connect the power steering cooler hoses to the CRFM. Refer to Power Steering Cooler Pipe/Hose Replacement (Power Steering Cooler Pipe/Hose Replacement).
25. Connect the radiator hoses to the water outlet housing and the coolant inlet pipe. Refer to Radiator Inlet Hose Replacement (LLT) (Radiator Hose).
26. Install the transmission oil cooler pipes to the engine, radiator and the transmission. Refer to Transmission Fluid Cooler Pipe Replacement - Front (Service and Repair) and to Transmission Fluid Cooler Pipe Replacement - Rear (Service and Repair).
27. Install the engine wiring harness and related components.




28. Install the HO2S connector bracket (1) to the left cylinder head.
29. Install the thermostat housing with the heater pipes, heater hoses and surge tank outlet hose. Refer to Engine Coolant Thermostat Housing Removal (9. Engine Coolant Thermostat Housing Removal).
30. Install the catalytic converters with the oxygen sensors. Refer to Catalytic Converter Replacement - Left Side (Catalytic Converter Replacement - Left Side) and to Catalytic Converter Replacement - Right Side (Catalytic Converter Replacement - Right Side).
31. Install the fuel lines to the fuel rail and the EVAP purge solenoid. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).

Note: Ensure that all the hoses, wires, pipes and shock modules clear the vehicle during the installation process.

32. With the aid of an assistant, raise the table or lift the vehicle to install the engine, transmission, front frame and front suspension assembly to the vehicle.




33. Install the front frame bolts (2). Refer to Drivetrain and Front Suspension Frame Replacement (Service and Repair).
34. Install the transmission support to underbody bolts. Refer to Transmission Support Replacement (Service and Repair).
35. Remove the powertrain lift/support table.




36. Install the upper mounting bolts to the right and left shock module. Refer to Shock Absorber and Spring Assembly Replacement (Shock Absorber and Spring Assembly Replacement).
37. Secure the shock modules to the front frame with mechanics wire to avoid stretching the front brake hoses.
38. Install the headlamp leveling sensors. Refer to Headlamp Leveling Front Suspension Height Sensor Replacement (Headlamp Leveling Front Suspension Height Sensor Replacement).




39. Connect the transmission shift linkage to the transmission.
40. Connect electrical connector to the low oil level sensor.




41. Install the lower engine mount nuts. Refer to Engine Mount Replacement - Left Side (Service and Repair) and to Engine Mount Replacement - Right Side (Service and Repair).
42. Install the lower intermediate steering shaft. Refer to Lower Intermediate Steering Shaft Replacement (without JL7) (Lower Intermediate Steering Shaft Replacement (without JL7))Lower Intermediate Steering Shaft Replacement (With JL7) (Lower Intermediate Steering Shaft Replacement (With JL7)).
43. Install the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation (Service and Repair).
44. Install the front brake pipes and retainers to the underbody.
45. Connect the rear brake pipes to the BPMV. Refer to Brake Pressure Modulator Valve Replacement (Service and Repair).
46. Connect the side air baffles to the radiator.
47. Install the washer bottle bracket. Refer to Windshield Washer Solvent Container Replacement (Without CE4) (Windshield Washer Solvent Container Replacement (Without CE4))Windshield Washer Solvent Container Replacement (With CE4) (Windshield Washer Solvent Container Replacement (With CE4)).
48. Install the air deflector. Refer to Front Air Deflector Replacement (Service and Repair).
49. Install the propeller shaft. Refer to Rear Propeller Shaft Replacement (All Wheel Drive) (Rear Propeller Shaft Replacement)Rear Propeller Shaft Replacement (Rear Wheel Drive) (Rear Propeller Shaft Replacement).
50. Install the muffler assembly. Refer to Exhaust System Replacement (Service and Repair).




51. Install the master cylinder. Refer to Master Cylinder Replacement (LHD) (Removal and Replacement).




52. Connect the engine harness electrical connector at the longitudinal rail.




53. Connect and lock the rear engine wiring harness electrical connector to the ECM.




54. Connect and lock the front engine wiring harness electrical connector to the ECM.





Caution: Refer to Fastener Caution (Fastener Caution).

55. Install the ground wire and bolt to the longitudinal rail and tighten to 10 Nm (89 lb in).
56. Connect the wiring harness to the transmission control module.




57. Connect the engine module wiring harness connectors (1-3) to the underhood electrical center. Refer to Underhood Electrical Center or Junction Block Replacement (Removal and Replacement).
58. Connect and lock the I/P electrical connector to the engine at the rear of the left Bank 2 cylinder head.
59. Connect the mass air flow sensor electrical connector.
60. Connect the electrical connector for the brake fluid level switch from the master cylinder.




61. Connect the brake booster vacuum hose (1) to the brake booster (2).




62. Install the radiator support brackets.
63. Install the radiator support bolts and tighten to 9 Nm (80 lb in).




64. Connect the purge line (3) to the purge solenoid.
65. Connect the fuel pipe (2) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
66. Connect the heater hoses to the heater core. Refer to Heater Inlet Hose Replacement (LH2) (Heater Inlet Hose Replacement)Heater Inlet Hose Replacement (LLT, LF1) (Heater Inlet Hose Replacement) and to Heater Outlet Hose Replacement (LH2) (Heater Outlet Hose Replacement)Heater Outlet Hose Replacement (LLT, LF1) (Heater Outlet Hose Replacement).
67. Install the air inlet duct.
68. Position and secure the surge tank inlet hose to the vehicle.
69. Connect the surge tank inlet hose to the water outlet housing and to the radiator. Refer to Radiator Surge Tank Outlet Hose/Pipe Replacement (LH2) (Radiator Surge Tank Outlet Hose/Pipe Replacement)Radiator Surge Tank Outlet Hose/Pipe Replacement (LLT) (Radiator Surge Tank Outlet Hose/Pipe Replacement).
70. Connect the outlet hose to the surge tank. Refer to Radiator Surge Tank Inlet Hose/Pipe Replacement (LH2) (Radiator Surge Tank Inlet Hose/Pipe Replacement)Radiator Surge Tank Inlet Hose/Pipe Replacement (LLT) (Radiator Surge Tank Inlet Hose/Pipe Replacement).
71. Connect the electrical connector for the air conditioning pressure switch and the liquid line to the evaporator. Refer to Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement (LH2) (Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement)Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement (LLT) (Air Conditioning Condenser and Air Conditioning Evaporator Tube Replacement).
72. Connect the air conditioning suction hose to the evaporator and install the suction hose bracket to the shock tower. Refer to Air Conditioning Compressor Hose Replacement (LLT) (Air Conditioning Compressor Hose Replacement)Air Conditioning Compressor Hose Replacement (LH2) (Air Conditioning Compressor Hose Replacement).




73. Install the air cleaner duct. Refer to Air Cleaner Inlet Duct Replacement (Service and Repair).




74. Install the cooling fan wiring harnesses (1, 4) to the fan shroud.
75. Install the cooling fan electrical connectors (2, 3).
76. Install the windshield wiper transmission. Refer to Windshield Wiper Transmission Replacement (Service and Repair).
77. Install the battery. Refer to Battery Replacement (Top Post) (Battery Replacement (Top Post))Battery Replacement (Side Post) (Battery Replacement (Side Post)).
78. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (LLT) (Fuel Injector Sight Shield Replacement).




79. Connect the positive cable to the battery and the underhood electrical center. Refer to Battery Positive Cable Replacement (LH2 With Top Post) (Battery Positive Cable Replacement (With Top Post))Battery Positive Cable Replacement (LH2 With Side Post) (Battery Positive Cable Replacement (With Side Post))Battery Positive Cable Replacement (LLT With Top Post) (Battery Positive Cable Replacement (With Top Post))Battery Positive Cable Replacement (LLT With Side Post) (Battery Positive Cable Replacement (With Side Post)).
80. Connect the negative cable from the battery and the body. Refer to Battery Negative Cable Replacement (LH2 with Top Post) (Battery Negative Cable Replacement (With Top Post))Battery Negative Cable Replacement (LLT With Side Post) (Battery Negative Cable Replacement (With Side Post))Battery Negative Cable Replacement (LLT With Top Post) (Battery Negative Cable Replacement (With Top Post))Battery Negative Cable Replacement (LH2 With Side Post) (Battery Negative Cable Replacement (With Side Post)).




81. Remove J 42640 from the steering column.
82. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (Cooling System Draining and Filling (Static Fill))Cooling System Draining and Filling (GE 47716) (Cooling System Draining and Filling (GE 47716)).
83. Charge the air conditioning system. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging).
84. Bleed the brake rear circuits. Refer to Hydraulic Brake System Bleeding (Pressure) (Service and Repair)Hydraulic Brake System Bleeding (Manual) (Service and Repair).