Installation

Engine Replacement

Installation Procedure

Notice: If the engine is damaged internally and a new engine assembly is installed in the vehicle, ensure that all foreign material is flushed out of the cooling system. You must also flush out the oil cooler system. Failure to rid the oil cooler system of debris can result in engine damage.

Tool Required
- J 41427 Engine Lift Bracket

1. Install the engine into the vehicle.




2. Install the engine mount through-bolts and nuts.
Tighten the engine mount through-bolts or the nuts to the following:
1. Tighten the through-bolts to 74 N.m (55 lb ft).
2. Tighten the nuts to 63 N.m (46 lb ft).
3. Remove the J 41427 and the engine lifting device.
4. Apply thread lock to the threads of the lower intake manifold bolts.
5. Install the intake manifold bolts.
1. Tighten the bolts the first pass to 3 N.m (27 lb in).
2. Tighten the bolts the first pass to 12 N.m (106 lb in).
3. Tighten the bolts the first pass to 15 N.m (11 lb ft).




6. Install the EGR valve inlet pipe to the intake and exhaust manifolds.
1. Tighten the EGR valve inlet pipe intake manifold nut to 25 N.m (18 lb ft).
2. Tighten the EGR valve inlet pipe exhaust manifold nut to 30 N.m (22 lb ft).
3. Tighten the EGR valve inlet pipe clamp bolt to 25 N.m (18 lb ft).
7. Install the water outlet.
8. Connect the fuel pipes at the rear of the engine.
9. Install the bolt holding the fuel pipe bracket to the rear of the left cylinder head.
Tighten the fuel pipe bracket bolt to 30 N.m (22 lb ft).
10. Connect the EVAP canister purge solenoid valve pipe.




11. Connect the vacuum brake booster hose to the intake manifold.
12. Install the distributor cap.
13. Install both of the AIR reactor pipes to the engine.
14. Install the AIR shut-oft valve and hoses.
15. Install the power steering pump mounting bracket.




16. Install the nuts holding the power steering pump rear bracket to the engine.
Tighten the power steering pump rear bracket nuts to 41 N.m (30 lb ft).
17. Install the nut holding the AIR reactor pipe bracket to the stud on the front of the engine.
Tighten the bolt to 30 N.m (22 lb ft).
18. Install the A/C compressor, if equipped.
19. Install the water pump pulley.




20. Install the accelerator control cable bracket to the throttle body.
Tighten the bolt to 9 N.m (80 lb in).

Caution: To help avoid potential personal injury or potential damage to the vehicle due to possible cable damage during service, replace the existing accelerator control cable with a NEW cable when removing or replacing the engine. Position the cruise control cable out of the way to ensure it is not damaged while removing or installing the engine. Do not bend the cruise control cable and cause a kink at the bend. Do not position the cruise control cable where the technician may lean or pry against the cable and cause damage to the cable.

21. Install a NEW accelerator control cable.
22. Install the cruise control cable, if equipped, to the throttle shaft and the accelerator cable bracket.




23. Install the battery ground cable bolt. Tighten
Tighten the ground cable bolt to 35 N.m (26 lb ft).




24. Install the bolts holding the ground wires to the left cylinder head.
Tighten the ground wire bolt to 35 N.m (26 lb ft).




25. Install the stud holding the ground wires to the right cylinder head.
Tighten the stud to 35 N.m (26 lb ft).




26. Position the engine wiring harness.
27. Install the engine wiring harness in the retainers.
28. Connect the following electrical connectors:
- The fuel meter body assembly
- The EVAP canister purge solenoid valve
- The idle air control (IAC) motor
- The throttle position (TP) sensor
- The A/C compressor high pressure switch, if equipped
- The A/C clutch switch, if equipped
- The exhaust gas recirculation (EGR) valve
- The engine coolant temperature (ECT) sensor
- The ignition control module (ICM)
- The generator
- The crankcase position (CKP) sensor
29. Install the radiator.
30. Install the inlet and outlet radiator hose to the engine.
31. Connect the heater hoses to the engine.




32. Raise the vehicle.
33. Install the transmission.
34. Install the transfer case, if equipped.
35. Install the front propeller shaft (Four Wheel Drive vehicle only).




36. Install the transmission cover
Tighten the nut to 12 N.m (106 lb in).
37. Install the starter.




38. Install the bolt holding the bracket for the starter wiring harness and if equipped, the transmission cooler lines.
Tighten the bracket bolt to 12 N.m (106 lb in).
39. Connect the oil cooler pipes (RWD vehicle).
40. Connect the remote oil filter inlet and outlet hoses (Four Wheel Drive vehicle).
41. Install the exhaust pipe to the exhaust manifolds.
42. Install a NEW oil filter.
43. Install the braces from the engine to the transmission.
44. Install the underbody shields.
45. Lower the vehicle.
46. Fill the engine with oil.
47. Fill the cooling system with coolant.
48. Connect the battery negative cable.
49. Recharge the air conditioning system, if equipped.
50. Operate and test the engine.