Engine - Installation

3.0L COMMON RAIL DIESEL ENGINE INSTALLATION





1. Carefully align the engine assembly in the engine bay area and align with the transmission, Do Not lower the engine.




2. Install left engine mount (3) to engine. Tighten bolts to 35 Nm (26 ft. lbs.).




3. Install right engine mount to engine (1). Tighten bolts to 35 N.m (26 ft. lbs.).




4. Align the engine to transmission, and lower the engine mounts into position.
5. Remove engine lifting device.
6. Route the transmission wiring harness through to the rear of the engine.
7. Raise and support the vehicle.
8. Install accessible engine to transmission housing bolts. Tighten bolts to 68 Nm (50 ft. lbs.).
9. Support the transmission and remove the rear transmission crossmember retaining bolts.
10. Lower the transmission and install the upper transmission to engine fasteners. Tighten bolts to 68 Nm (50 ft. lbs.).
11. Raise the transmission and install the transmission crossmember.
12. Install the flex plate to torque converter bolts (1).
13. Tighten engine mount through bolts to 30 Nm (22 ft. lbs.). 




14. Install the engine ground wire above the starter (1). Tighten bolt to 14 Nm (10 ft. lbs.).
15. Install the starter wiring.




16. Connect the crankshaft sensor (2) wiring harness connector.
17. Route the transmission wiring harness and make necessary sensor connections at the transmission.
18. Install the front axle housing Installation. 




19. Install the catalytic converter and front exhaust pipe (2).
20. Install the transfer case shield.
21. Lower the vehicle.




22. Install the fuel supply and return lines to the fuel pipe.




23. Attach the axle vent tube to the wiring harness.
24. Secure the transmission oil level indicator.
25. Install the engine cover bracket.
26. Connect the A/C lines (1) at the expansion valve.
27. Connect the coolant hose, at the outer housing, by the generator.
28. Connect the coolant by-pass hose at the cooler tube (2) on the right cylinder head.
29. Connect the heater hose, at the cooler tube (2) on the right cylinder head.




30. Connect the wiring harness connectors to the PDC (1).
31. Connect the vacuum hose to the vacuum pump.
32. Connect the generator wiring.
33. Connect the A/C compressor wiring harness connector.
34. Connect the PCM wiring harness connectors.
35. Install the PDC (1) bracket and mount the PDC (1).

NOTE: Do Not connect the negative battery cable when installing the battery.

36. Install the battery (4) and tray.




37. Install the coolant module assembly.
38. Connect the transmission cooler (3) and power steering cooler (4) lines to the coolant module.
39. Connect the suction / discharge lines at the A/C condenser and accumulator.
40. Connect the power steering reservoir hose to pump, at the reservoir.
41. Install the charge air inlet and outlet hoses at cooler (5).
42. Install the front core support bracket.
43. Install the front grille and upper radiator core support bracket with the hood latch.
44. Raise and support the vehicle.




45. Install the power steering hydraulic lines at cooling fan Power Steering Hoses - Installation.
46. Install the lower radiator hose.
47. Lower the vehicle.
48. Install lower catalytic converter exhaust clamp (1) behind right cylinder head.




49. Install the turbocharger (3) upper heat shield.
50. Install air cleaner housing and connect the air cleaner outlet tube (1) to the turbocharger.
51. Install the strut tower support (2).
52. Fill all appropriate fluid levels.
53. Evacuate and recharge air conditioning.
54. Connect the negative battery cable.
55. Start engine, allow to warm, turn engine off and inspect for leaks. Vehicle Damage Warnings
56. Bleed power steering system using the scan tool procedure.
57. Install lower splash shields.




58. Install engine cover (3).