Engine - Installation - Body Off
Engine - Body Off
Installation
NOTE: It is recommended that this component be serviced with the vehicle body removed. If the body was not removed, refer to Engine - Body On Engine - Installation - Body On.
Vehicles with manual transmission
1. Install the clutch disc and pressure plate. For additional information, refer to Clutch, M/T.
All vehicles
2. NOTE: Automatic transmission shown, manual transmission similar.
With the help of an assistant, using the Heavy Duty Floor Crane and Engine Lifting Brackets, position the engine in the vehicle. Install the 4 upper engine-to-transmission bolts.
- Tighten to 47 Nm (35 lb-ft).
3. Remove the transmission jack.
4. NOTICE: Only use hand tools when installing the center bolt or damage to the center bolt may occur.
Lower the engine and install the new LH engine mount center bolt.
- Tighten to 350 Nm (258 lb-ft).
5. NOTE: Failure to remove the rear factory lifting bracket may result in a NVH concern.
If installing a new factory engine, remove the 2 bolts and the rear factory lifting bracket.
Vehicles with dual generators
6. Install the secondary generator. For additional information, refer to Charging System.
All vehicles
7. NOTE: Install a new clamp on the crankcase vent oil separator.
Install the Air Cleaner (ACL) outlet pipe and tighten the clamp. Connect the crankcase vent tube.
- Tighten to 5 Nm (44 lb-in).
8. Roll the chassis back to the markings on the floor.
9. Position back the power steering hose and connect the retainer.
10. Connect the retainers for the power steering hose.
Vehicles with automatic transmission
11. Install 8 new torque converter nuts.
- Tighten to 35 Nm (26 lb-ft).
12. Install the flexplate access cover.
All vehicles
13. Connect the fuel hoses.
14. Position back the transmission cooler tubes and install the nut.
- Tighten to 9 Nm (80 lb-in).
15. If equipped, position back the steering damper and install the nut and bolt.
- Tighten to 35 Nm (26 lb-ft).
16. Position back the battery ground cable and install the bolt.
- Tighten to 47 Nm (35 lb-ft).
17. NOTE: RH side shown, LH side similar.
NOTE: Verify that the marks are aligned prior to tightening the bolts.
Install the front bumper and 6 bolts.
- Tighten to 47 Nm (35 lb-ft).
18. Install the 2 retaining nuts for the starter solenoid wiring.
- Tighten the large nut to 12 Nm (106 lb-in).
- Tighten the small nut to 6 Nm (53 lb-in).
19. Install the cover for the starter wiring.
20. Position back the battery cable bracket and install the nut.
- Tighten to 25 Nm (18 lb-ft).
21. If equipped, connect the block heater electrical connector.
Vehicles with automatic transmission
22. Install the transmission fluid level indicator and tube. Install the nut.
- Tighten to 8 Nm (71 lb-in).
All vehicles
23. NOTE: Install a new gasket and turbocharger clamp.
Position the turbocharger exhaust downpipe and loosely install the turbocharger exhaust downpipe clamp.
- Make sure the exhaust downpipe clip is over the lip on the turbocharger.
- Align the new exhaust downpipe-to-turbocharger clamp so that the exhaust downpipe clip and the opening in the exhaust downpipe-to-turbocharger clamp are aligned and tightened to maintain position.
- Align the downpipe so that the area just above the flat in the pipe is approximately 20 mm (0.787 in) from the frame.
24. Install the 2 exhaust downpipe bolts.
- Tighten to 40 Nm (30 lb-ft).
25. Tighten the turbocharger exhaust downpipe clamp.
- Tighten to 15 Nm (133 lb-in).
26. Install the body.
27. NOTE: Automatic transmission shown, manual transmission similar.
Install the 5 lower engine-to-transmission bolts.
- Tighten to 47 Nm (35 lb-ft).
28. NOTICE: Only use hand tools when installing the transmission mount retaining nuts or damage to the transmission mount may occur.
Remove and discard the 2 transmission mount retaining nuts. Install the 2 new transmission mount retaining nuts.
- Tighten to 115 Nm (85 lb-ft).
29. NOTICE: Only use hand tools when installing the engine mount retaining nuts or damage to the engine mount may occur.
Install the 3 new LH engine mount retaining nuts.
- Tighten to 200 Nm (148 lb-ft).
30. NOTICE: Only use hand tools when installing the engine mount retaining nuts or damage to the engine mount may occur.
Install the 4 new RH engine mount retaining nuts.
- Tighten to 115 Nm (85 lb-ft).
31. Fill the engine with the correct motor oil for the climate. For additional information, refer to Engine Engine.
32. Charge the A/C system. For additional information, refer to Heating and Air Conditioning.
33. Connect the battery ground cable(s). For additional information, refer to Battery.
34. Bleed the low-pressure and high-pressure fuel system. For additional information, refer to Fuel Delivery and Air Induction.
35. Fill and bleed the power steering system. For additional information, refer to Steering.
36. NOTE: Clearing the DTCs or Keep Alive Memory (KAM) does not reset the adaptive values in the PCM.
If the high-pressure fuel injection pump or fuel injector(s) were replaced, clear the fuel injector adaptive tables from the PCM, using the scan tool. For additional information, refer to Computers and Control Systems Information.
37. NOTE: Clearing the DTCs or KAM does not reset the adaptive values in the PCM.
If the EGR valve was replaced, clear the EGR adaptive tables from the PCM, using the scan tool. For additional information, refer to Computers and Control Systems Information.