Part 1
Engine
Installation
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Vehicle Jacking and Lifting.
2. NOTE: The engine must be to the left of the center line to install.
Raise the engine high enough to clear the No. 1 crossmember and position the engine into the vehicle.
3. NOTE: Left side shown, right side similar.
Position the engine mounts in the vehicle.
4. Align the torque converter studs with the holes in the flywheel and push the engine in. Install the top 4 engine-to-transmission bolts.
- Tighten to 47 Nm (35 lb-ft).
5. Lower the engine until it is just above the motor mounts and install the 4 RH engine mount bolts.
- Tighten to 80 Nm (59 lb-ft).
6. Install the 4 LH engine mount bolts.
- Tighten to 80 Nm (59 lb-ft).
7. Remove the transmission jack.
8. Install a new O-ring seal on the oil pickup tube and position the oil pickup tube in the oil pan.
9. Install a new press-in-place gasket into the upper oil pan.
10. Position the oil pan in the vehicle.
11. Install the oil pickup tube and 2 bolts.
- Tighten to 13 Nm (115 lb-in).
12. Position the oil pan and install the bolts.
1. Install the 5 longer oil pan bolts.
2. Install the 15 remaining oil pan bolts.
- Tighten to 13 Nm (115 lb-in).
13. Clean and inspect the oil pan drain plug and gasket. Install new, if necessary.
14. Install the oil pan drain plug.
- Tighten to 44 Nm (32 lb-ft).
15. Lower the engine.
16. Install the factory engine lifting bracket and 2 bolts.
17. Position the ground strap and install the bolt.
- Tighten to 12 Nm (106 lb-in).
18. Loosely install the turbocharger exhaust pipe.
19. NOTE: Remove the plug or cap as needed.
Install the Injection Control Pressure (ICP) sensor.
- Tighten to 12 Nm (106 lb-in).
20. NOTE: Remove the protective covering from the cylinder head.
Install the LH valve cover gasket, valve cover and 11 bolts.
- Tighten to 9 Nm (80 lb-in).
21. Install the glow plug module mounting bracket and the 3 nuts.
- Tighten to 8 Nm (71 lb-in).
22. Install the glow plug module and the 2 nuts.
- Tighten to 8 Nm (71 lb-in).
23. Connect the Exhaust Pressure (EP) tube to the exhaust manifold.
- Tighten to 30 Nm (22 lb-ft).
24. NOTE: Install a new O-ring seal and lubricate with clean engine oil prior to installation.
Position the oil indicator and tube, install the retaining nut and connect the glow plug wire retainer.
- Tighten to 8 Nm (71 lb-in).
25. Position the fuel tubes and install the 2 mounting bolts for the fuel tube bracket.
26. Install the 2 lower engine-to-transmission bolts.
- Tighten to 47 Nm (35 lb-ft).
27. NOTE: Left side shown, right side similar.
NOTE: The top retaining nut must be tightened first.
Install the 4 engine mount-to-crossmember nuts.
- Tighten to 90 Nm (66 lb-ft).
28. Install the starter motor, stud bolt and 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
29. Connect the starter positive cable nut.
- Tighten to 14 Nm (124 lb-in).
30. Connect the starter control wire nut.
- Tighten to 6 Nm (53 lb-in).
31. Install the starter motor solenoid protective cap.
32. Position the battery cable bracket and install the nut.
- Tighten to 22 Nm (16 lb-ft).
33. Connect the block heater electrical connector.
34. Install the 6 new torque converter nuts.
- Tighten to 35 Nm (26 lb-ft).
35. Install the torque converter cover.
36. Position the transmission cooler tube support bracket on the stud and install the nut.
- Tighten to 12 Nm (106 lb-in).
37. Install the engine-to-transmission bolt for the transmission cooler tubes.
- Tighten to 47 Nm (35 lb-ft).
38. Install the oil filter assembly and the 3 bolts.
- Tighten to 24 Nm (18 lb-ft).
39. NOTICE: Fully seat the PCM electrical connectors prior to latching the electrical connectors or damage to the connector pins may occur.
Position the engine wiring harness and connect the PCM electrical connectors.
40. Connect the 2 engine-to-vehicle electrical connectors.
