Engine - Installation

INSTALLATION

Special Tools:











NOTE: If installing a replacement engine, transfer components such as engine mount brackets, block heater, accessories, heater hoses and tubes to the replacement engine.

1. If required, remove the upper intake manifold Intake Manifold - Removal





2. Install the Driver Side Engine Lifting Bracket (1) on the LH cylinder head with bolts (2) provided with the Engine Lifting Bracket. Tighten the bolts to 21 Nm (15 ft. lbs.).





3. Install the Passenger Side Engine Lifting Bracket (1) on the RH cylinder head with bolts (2) provided with the Engine Lifting Bracket. Tighten the bolts to 21 Nm (15 ft. lbs.).





4. Position a load-leveling lifting sling (2), such as OTC(R) 4305 Engine Load Leveler or equivalent, between the engine lifting brackets (3) and an engine hoist (1).
5. Reposition the starter wire harness and the main wire harness to the rear of the engine compartment.






NOTE: Left engine mount shown, right engine mount similar.

6. Position the engine in the vehicle while aligning the two locator dowels into the transmission housing.
7. Align the tab on the isolators (3) with the notch in the engine mount brackets (2) and lower the engine so the weight is resting on the isolators.
8. Install the left and right engine mount nuts (1) and tighten to 61 Nm (45 ft.lbs.).





9. Remove the engine lifting brackets and install the LH upper intake manifold support brackets (1). Loosely install the studbolts (2).





10. Route the main wire harness and starter wire harness on the engine.
11. Engage two starter wire harness retainers (1) to the upper intake manifold support brackets.
12. Engage one main wire harness retainer (3) to the left cylinder head cover and two retainers (2) to the upper intake manifold support brackets.





13. Connect the Engine Coolant Temperature (ECT) sensor connector (3).
14. Connect the left Camshaft Position (CMP) sensor (5).
15. Engage one main wire harness retainer (2) to the cylinder head cover and one main wire harness retainer (4) to the cylinder head cover mounting stud.
16. Engage the main wire harness retainer (1) to the rear of the lower intake manifold.





17. Connect the electrical connector (1) to the right Camshaft Position (CMP) sensor.
18. Engage the main wire harness retainer (2) to the right cylinder head cover mounting stud.





19. Engage four main wire harness retainers (1) to the right cylinder head cover.





20. Connect the electrical connectors (2) to the variable valve timing solenoids on the right cylinder head.
21. Engage two starter wire harness retainers (1) to the right cylinder head cover.
22. Engage the starter harness to main harness retainer (3).





23. Connect the oil pump solenoid electrical connector (2).
24. Engage four wire harness retainers (1).
25. Install the ground strap (3) to the right engine mount bracket.





26. Raise and support the vehicle Maintenance.
27. Install four transmission to engine oil pan bolts (1). Tighten the bolts to 55 Nm (41 ft. lbs.).





28. Install two rubber plugs (1) covering the rear oil seal retainer flange bolts.





29. Install the side engine to transmission bolt (1). Tighten the bolt to 55 Nm (41 ft. lbs.).
30. Install the torque converter dust shield (3) with the bolt (2). Tighten the bolt to 12 Nm (106 in. lbs.).






NOTE: If equipped with AWD, the rear of the engine must be lowered in order to access the upper transmission to engine bolts.

31. If equipped with AWD, support the transmission with a suitable jack, remove three crossmember brace bolts (1), six crossmember bolts (2) and adjust the jack to lower the rear of the engine.





32. Install the four upper transmission to engine bolts (1). Tighten the bolts to 55 Nm (41 ft. lbs.).





33. Install the bolt (1) securing the transmission fluid level indicator tube (2) to the transmission housing and tighten to 12 Nm (106 in. lbs.).





34. Connect the main harness to the engine injection/ignition harness (1) at the rear of the left cylinder head.
35. Connect the main harness to the engine oil pressure/temperature harness (2) at the rear of the left cylinder head.





36. If equipped with AWD, raise the rear of the engine, reinstall six crossmember bolts (2) and three crossmember brace bolts (1). Tighten all bolts to 55 Nm (41 ft. lbs.).





37. Rotate the crankshaft in a clockwise direction and install the six torque converter bolts (1) through the starter mounting. Tighten the bolts to 42 Nm (31 ft. lbs.).





38. Clip the transmission cooler line retainer (1) to the oil pan flange.





39. Engage the starter wire harness retainer (2) and the main wire harness retainer (1) to the engine block.
40. Install the starter Starter - Installation.





41. Connect the power cord to the engine block heater (if equipped).
42. Connect the main wire harness to the Crankshaft Position (CKP) sensor (3).
43. Engage one main wire harness retainer (1) to the engine block and one main wire harness retainer (2) to the right engine mounting bracket.





44. Position the heatshield (1) over the crankshaft position (CKP) sensor.





45. If equipped with AWD, install the front axle (1) Installation.





46. Lower the vehicle.
47. If equipped with AWD, engage the transfer case vent hose retainer (1) to the upper intake manifold support bracket (2).





48. Install the heater core supply tube (1) with one bolt (2) tightened to 12 Nm (106 in. lbs.).





49. Install the oil level indicator (2) with bolt (1) tightened 12 Nm (106 in. lbs.).





50. Install the A/C compressor (2) with three bolts (1) tightened to 25 Nm (18 ft. lbs.).





51. Connect the heater core return hose (1).





52. Install the lower radiator hose (1) to the engine coolant pump housing.





53. Install the upper radiator hose (1) to the engine thermostat housing.





54. Connect the electrical connectors (2) to the left variable valve timing solenoids.
55. Engage two starter wire harness retainers (1) to the left cylinder head cover.





56. Connect the A/C compressor electrical connector (1) and Engage the wire harness retainer (2) to the A/C compressor discharge line.






NOTE: Left engine mount shown, right engine mount similar.

57. Install the engine mount heatshield (2) to both the left and right engine mounts with two bolts (1) tightened to 12 Nm (106 in. lbs.).






NOTE: Right catalytic converter shown, left catalytic converter similar.

58. Install the right and left catalytic converters (2) onto the partially installed lower catalytic converter flange bolts (3).
59. Install the upper catalytic converter flange bolts (1) and tighten all M8 bolts to 23 Nm (17 ft. lbs.).
60. Connect the right and left upstream oxygen sensor connectors (4) to the main wire harness.





61. Install the generator (1) Generator - Installation.
62. Install the accessory drive belt (3) Serpentine Accessory Drive Belt - Installation.





63. Install the cooling fan module Cooling Fan - Installation.





64. Connect the fuel supply hose (1) to the underbody fuel tube (2) Service and Repair





65. Install the make-up air tube (3) to the left cylinder head cover and engage the clips (1) to the transmission breather hose (2).





66. Install the upper intake manifold and insulator Intake Manifold - Installation





67. Install the PCV hose (1) to the PCV valve (2).





68. Install the vapor purge tube (1) to the fuel purge solenoid (2) Service and Repair





69. Install the nut (2) to the support bracket of the heater core return tube (3) and tighten to 12 Nm (106 in. lbs.).





70. Raise and support the vehicle Maintenance.
71. Install the A/C compressor mounting stud (2) and tighten to 25 Nm (18 ft. lbs.).
72. Install the nut (1) and bolt (4) to the support brackets of the heater core return tube (3). Tighten to 12 Nm (106 in. lbs.).
73. If equipped, install the transfer case skid plate, the transmission skid plate, the front suspension skid plate and the front skid plate.





74. Lower the vehicle.
75. Install the electric vacuum pump (4) and mounting bracket (1) Installation.





76. Install the resonator (3) and the air cleaner body Air Cleaner Body - Installation





77. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level Service and Repair
78. Fill the cooling system Service and Repair.
79. Install the engine cover (1).
80. Install the hood Hood - Installation.
81. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.).
82. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level Service and Repair

NOTE: The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components.