Engine - Installation

INSTALLATION - ENGINE - HEV

WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury Service Precautions






NOTE: Do not use air tools to install the engine lift fixture (1) 8984A and engine lift fixture adapter 8984-Eagle.

1. Install the engine lift fixture (1) 8984A and engine lift fixture adapter 8984-Eagle (2).
2. Apply a light coating of Mopar(R) High Temp Grease to the transmission damper hub pocket in the rear of the engine crankshaft.
3. Using a suitable engine hoist position the engine into the engine compartment.





4. Remove the engine hoist and install the engine support fixture 8534B (3).
5. Using the engine support fixture, raise the engine several inches to gain access the differential bracket to engine block front bolt.
6. Raise and support the vehicle.





7. Position the differential bracket (2) and install the differential bracket to engine block front bolt (1) and tighten bolt to 68 Nm (50 ft. lbs.).
8. Lower the vehicle.





9. Using the engine support fixture 8534B, lower and align the engine (2) with the transmission (1).

NOTE: Verify that no wires, or the transmission vent hose have become trapped between the engine block and the transmission.

10. Install the two upper transmission bell housing to engine block bolts (2) finger tight.





11. Lower the engine assembly until the engine mounts (1) lineup in the frame brackets.
12. Install both front engine mount through bolts (2) (left side shown, right side similar).
13. Raise and support the vehicle.
14. Tighten both front engine mount through bolts/nuts to 95 Nm (70 ft. lbs.)





15. Install the differential bracket to engine block rear bolt (2) and tighten to 68 Nm (50 ft. lbs.).
16. Install the three differential bracket bolts (1) at the differential and tighten to 95 Nm (70 ft. lbs.).





17. Install the remaining transmission (1) bell housing to engine (2) bolts and tighten the lower 4 bolts to 54 Nm (40 ft. lbs.) and the upper 2 bolts to 41 Nm (30 ft. lbs.).






CAUTION: It is essential that the correct length bolts be used to attach the transmission damper to the flexplate. Bolts that are too long will cause damage to the transmission.

18. Rotate the crankshaft in a clockwise direction and install the four damper-to-flexplate bolts (1) hand tight.
19. Rotate the crankshaft in a clockwise direction and tighten the damper-to-flexplate bolts (1) to 31 Nm (23 ft. lbs.).






CAUTION: The structural dust cover must be installed as described in the Structural Dust Cover installation procedure. Failure to do so will cause severe damage to the cover.

20. Install the engine structural dust cover (2) Structural Dust Cover - Installation

CAUTION: The propeller shaft must be installed as described in the Propeller Shaft installation procedure. Failure to do so may result in a driveline vibration.

21. Install the front propeller shaft Drive Shaft - Installation





22. Install a new gasket to the transmission auxiliary oil pump.
23. Position the transmission auxiliary oil pump (2) and install the four bolts (1) and tighten to 11 Nm (8 ft. lb.).





24. Position the left exhaust pipe/catalytic converter assembly (3) and align the right exhaust pipe/catalytic converter assembly (2) and install the new exhaust crossover clamp and retaining bolt (1) hand tight.





25. Connect both front exhaust pipe/catalytic converter assemblies (4) at the exhaust manifolds and install the exhaust pipe to manifold bolts (3) (left side shown, right side similar) and tighten the manifold flange bolts to 34 Nm (24 lbs. ft.).
26. Tighten the new exhaust crossover clamp and retaining bolt to 61 Nm (45 lbs. ft).
27. Connect all four oxygen sensor electrical connectors (2).






NOTE: Coat the cylinder block drain plug threads with Mopar(R) Thread Sealant with Teflon prior to installation.

28. Install the cylinder block drain plugs (1) and tighten to 34 Nm (25 ft. lbs.).





29. Position the electrical harness and connect the electrical connectors to the knock sensor (1) and the crankshaft position sensor (2).





30. Connect the electrical connectors to the oil temperature sensor (1) and the oil pressure sensor (3).
31. Install the ground cable and the retaining bolt/stud (2) and securely tighten.
32. Install a new oil filter.





33. Position the A/C compressor to the engine and install the three studs (2) and nuts (1) and tighten the studs to 10 Nm (7 ft. lbs.) and the nuts to 25 Nm (18 ft. lbs.)

CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system Refrigerant Oil Capacity . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage.

CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment.

NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemRefrigerant Oil Capacity

NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak.






CAUTION: Always use ND-11 POE refrigerant oil from Mopar(R) in an Hybrid Electric Vehicle (HEV) model. Never use PAG oil in an HEV model. Never use POE oil in gasoline models. Never mix PAG and POE oils. See Refrigerant Oil for more information.

34. Remove the tape or plugs from the open suction line fitting and the compressor port.
35. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the suction line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only ND-11 POE refrigerant oil from Mopar(R) in an Hybrid Electric Vehicle (HEV) model.
36. Position the A/C suction line (2) and the A/C discharge line (4) to the A/C compressor (5) and tighten the nuts (3) to 23 Nm (17 ft. lbs.) A/C Suction Line - Installation and A/C Discharge Line - Installation
37. Install the suction line retaining bracket (1) to the front of the engine and securely tighten.





38. Position and connect the orange High Voltage (HV) cable to the retainers at the front of the engine.
39. Connect and lock the orange HV connector (4) to the A/C compressor (6). Make sure the connector is fully engaged and locked.
40. Connect the black Low Voltage (LV) connector (2) and engage the grey Connector Position Assurance (CPA) latch (1). This locks the LV and HV connectors in place. The electrical connections are correctly assembled when the red tab (3) sticks out from the outboard side of the HV connector.





41. Position the ground cable (2) located in front of the left engine mount and securely tighten the ground cable bolt (1).

42. Position the electrical harness and connect the left knock sensor electrical connector.
43. Lower the vehicle.




44. Remove the engine support fixture 8534B (3), engine lift fixture (1) 8984A and the engine lift fixture adapter 8984-Eagle (2).





45. Rotate the oil control valve (OCV) left and right until completely seated into the cylinder block.
46. Ensure that the O-ring is fully seated into the cylinder block.





47. Securely tighten the OCV fastener (1).
48. Connect the OCV electrical connector (2).





49. Apply Mopar(R) Lock & Seal Adhesive to the intake manifold retaining bolts.
50. Install new intake manifold seals (3) and positive crankcase ventilation (PCV) seals (1).





51. Connect the manifold air pressure (MAP) sensor (1) connectors as you position the intake manifold in place.





52. Using the sequence shown, install the intake manifold retaining bolts and tighten the bolts to 12 Nm (9 ft. lbs.).





53. Connect the fuel supply line quick connect fitting at the fuel rail (1) and install the safety retainer clip Service and Repair

NOTE: The factory fuel injection electrical harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If the harness was not tagged, use injector position location noted during removal.

54. Reposition the fuel injector electrical harness and connect the electrical connectors to all fuel injectors.
55. Connect the break booster vacuum hose at the back of the intake manifold.
56. Connect the vacuum hose located at the front of the intake manifold near the throttle body.





57. Position the EGR valve routing tube (2) and securely tighten retainers.





58. Position the electrical harness and connect the electrical connectors to the EGR valve (1), throttle body (2) and the coolant temperature sensor (3).





59. Install the radiator crossmember (1) and tighten bolts (2) to 31 Nm (23 ft. lbs.).Radiator Upper Crossmember - Installation





60. Position the hood latch (4) lining up the marks made previously and install the center brace mounting bolts and tighten to 11 Nm (8 ft. lbs.).






CAUTION: Do not use a hammer or mallet to install the upper radiator shroud push pins, due to potential damage to the grille.

NOTE: Aspen grille shown, Durango grille similar.

61. Install the grille (3).
62. From underneath, install the four screws (2) and tighten to 13 Nm (10 ft. lbs.).
63. Install the upper four screws (1) and tighten to 13 Nm (10 ft. lbs.).
64. Install the radiator, cooling fan and the transmission oil cooler as an assembly Engine Cooling Radiator - Installation and Installation
65. Install the condenser and cooling fan as an assembly A/C Condenser - Installation





66. Install the upper radiator support (3) and tighten the bolts (2) to 11 Nm (8 ft. lbs.).





67. Install the electric vacuum pump (2) Installation





68. Connect the heater hoses (1,3) and the lower radiator hose (2).
69. Connect the upper radiator hose.
70. Connect the overflow tube.





71. Install the electrical harness (3) push-pin retainers (2) into the fan shroud.
72. Connect the radiator fan electrical connector (1).





73. Install the push-pin retainers (1) and the upper condenser/radiator seal (2).





74. Install the traction power inverter module (TPIM) (1) TPIM/Transmission Cooler - Installation
75. Remove the traction power inverter module (TPIM) coolant recovery bottle TPIM Coolant Recovery Container - Removal





76. Position the high voltage cables and lower the high voltage cable retainer assembly (2) into the support bracket.
77. Install the high voltage cable support bracket retaining nuts (1) securely tighten nuts.





78. Position the MDS electrical harness (2), located at the back of the left cylinder head and connect the MDS electrical connector (1).

79. Raise and support the vehicle.





80. Position the transmission fluid cooler lines (1) and connect the cooler lines into the transmission fittings (2).





81. Position the lower radiator hose onto the radiator and reposition the lower radiator hose clamp (2).
82. Connect the transmission fluid cooler lines to the retainers at the oil pan.
83. Connect the transmission fluid cooler lines (1) to the transmission cooler.





84. Position the TPIM coolant pump and bracket (1) onto the radiator (1).
85. Install the TPIM coolant pump mounting bolts (2) and tighten to 8.5 Nm (75 in. lbs.).





86. Connect the TPIM cooling hose (1) and position the hose clamp.
87. Position the electrical harness and connect the electrical connectors (2).





88. Position the TPIM cooler extension lines and clip lines into the retaining clips at the radiator shroud.
89. Connect the TPIM cooler extension lines position the hose clamps.





90. Securely tighten the radiator petcock (1).
91. Securely tighten the TPIM drain plug (2).
92. Lower the vehicle.





93. Install the HVAC air inlet duct (2) and securely tighten the retaining nuts (1).





94. Install the HVAC air inlet baffle/plenum (2) into the air inlet duct retaining clips (1).





95. Verify the throttle body seal is properly aligned at the bottom of the air cleaner housing.
96. Slide the rear air cleaner housing pegs (2) into the grommets (1) on the rear of the intake manifold and lower the front of the air cleaner housing onto the throttle body.

NOTE: Verify the air cleaner housing is installed properly in the rear grommets by reaching around the left rear corner of the air cleaner housing and feel for the pegs protruding through the rubber grommets. If the plastic pegs cannot be felt, the air cleaner housing will need to be reinstalled.






97. Install the air cleaner housing center fastener (2) and tighten to 7 Nm (62 in. lbs.)
98. Install the air cleaner trim cover.
99. Connect the intake air temperature (IAT) sensor electrical connector (1).





100. Install the clean air tube (2).
101. Install the clean air tube fastener (3) and tighten to 7 Nm (62 in. lbs.).
102. Connect the high voltage inter lock (HVIL) electrical connector.
103. Connect the brake booster hose and positive crankcase ventilation (PCV) hose.





104. Install the cowl grille (4), and the cross-bar beam Cowl Panel Cover - Installation





105. Install the hood (1) Hood - Installation
106. Fill crankcase with oil
107. Fill the cooling system Service and Repair






NOTE: For proper connections, ensure that the two battery cables (3) are positioned as observed during removal and DO NOT stack the crimp of the top terminal directly above the crimp of the bottom terminal.

108. Position the battery cable junction block with the tab in the alignment hole and securely tighten the battery cable junction block retainer bolt (4).
109. Position the positive battery cables (3) over the studs and install the positive battery cable nuts (2) and tighten the nuts to 10 Nm (90 in. lbs.).
110. Secure the positive battery cable access cover (1).





111. Connect the 12 volt battery system ground isolation connector (1) and secure the connector to the electric vacuum pump bracket (2).
112. Connect the vacuum hose (3) to the electric vacuum pump.
113. Connect the electric vacuum pump electrical connector (4).

NOTE: It is critical to use the recommended oil viscosity in 5.7L engines that use MDS. Refer to the engine oil filler cap for the recommended engine oil viscosity.

114. Fill the engine with the recommended engine oil.
115. Fill the TPIM cooling system TPIM Cooling System Filling
116. Fill the cooling system and purge Service and Repair
117. Perform the HEV power up procedure Battery System - High Voltage Power Up
118. Start the engine and inspect for leaks.

NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemRefrigerant Oil Capacity

CAUTION: Always use ND-11 POE refrigerant oil from Mopar(R) in an Hybrid Electric Vehicle (HEV) model. Never use PAG oil in an HEV model. Never use POE oil in gasoline models. Never mix PAG and POE oils. See Refrigerant Oil for more information.

119. Charge the A/C refrigerant system Refrigerant System Charge
120. Road test the vehicle.