Engine - Installation
INSTALLATION
Special Tools:
NOTE: If installing a replacement engine, transfer components such as engine mount isolators, block heater, accessories, heater hoses and tubes to the replacement engine.
1. If required, remove the upper intake manifold (2) Intake Manifold - Removal
2. Install the Driver Side Engine Lifting Bracket (1) on the LH cylinder head with bolts (2) provided with the Engine Lifting Bracket. Tighten the bolts to 21 Nm (15 ft. lbs.).
3. Install the Passenger Side Engine Lifting Bracket (1) on the RH cylinder head with bolts (2) from the Engine Lifting Bracket. Tighten the bolts to 21 Nm (15 ft. lbs.).
4. Position a load-leveling lifting sling (2), such as OTC(R) 4305 Engine Load Leveler or equivalent, between the engine lifting brackets (3) and an engine hoist (1).
5. Reposition the main wire harness to the rear of the engine compartment.
NOTE: Right engine mount shown, left engine mount similar.
6. Position the engine in the vehicle. If equipped with an automatic transmission, align the two locator dowels into the transmission housing.
7. Align the left and right engine mount isolators (1) within the frame mounting brackets and lower the engine so the weight is resting on the mounting bolts (2).
8. Tighten the left and right engine mount nuts (3) to 61 Nm (45 ft. lbs.).
9. Install the engine mount heatshield (1) to the left engine mount with two bolts (2) tightened to 12 Nm (106 in. lbs.).
10. Raise and support the vehicle Maintenance.
11. Install the manual transmission, if equipped NSG370 Manual Transmission - Installation.
12. If equipped with an automatic transmission, install the four upper transmission to engine bolts (1). Tighten the bolts to 55 Nm (41 ft. lbs.).
13. If equipped with an automatic transmission;
- Install four transmission to the engine oil pan bolts (2 and 3) and tighten to 55 Nm (41 ft. lbs.).
- Install two rubber plugs (1) covering the rear oil seal retainer flange bolts.
14. If equipped with an automatic transmission;
- Install the side engine to transmission bolt (1). Tighten the bolt to 55 Nm (41 ft. lbs.).
- Install the torque converter dust shield (3) with the bolt (2). Tighten the bolt to 12 Nm (106 in. lbs.).
15. If equipped with an automatic transmission, engage the transmission cooler line retainer (1) to the oil pan flange.
16. If equipped with an automatic transmission, rotate the crankshaft in a clockwise direction and install the six torque converter bolts (1) through the starter mounting. Tighten the bolts to 42 Nm (31 ft. lbs.).
17. Connect the power cord to the engine block heater (if equipped).
18. Install the ground straps (1) with one nut (2) tightened to 12 Nm (106 in. lbs.).
19. Install the starter Starter - Installation.
20. Install the A/C compressor (2) onto the engine with four bolts (1) tightened to 28 Nm (21 ft. lbs.).
NOTE: Right catalytic converter shown, left catalytic converter similar.
21. Install the right and left catalytic converters Catalytic Converter - Installation.
22. Connect the right and left upstream (3) and downstream (1) oxygen sensor connectors to the main wire harness.
23. Route the main wire harness on the left side of the engine.
24. Connect the A/C compressor electrical connector (2).
25. Connect the left exhaust variable valve timing solenoid electrical connector (4).
26. Connect the left intake variable valve timing solenoid electrical connector (3).
27. Engage three wire harness retainers (1) to the left cylinder head cover.
28. Connect the Engine Coolant Temperature (ECT) sensor connector (3).
29. Connect the left Camshaft Position (CMP) sensor (1).
30. Engage the main wire harness retainer (2) to the cylinder head cover mounting stud.
31. Connect the left upstream oxygen sensor (1) and the left downstream oxygen sensor (2) electrical connectors.
32. Route the main wire harness on the right side of the engine.
33. Install the B+ terminal to the generator stud (2) and tighten the nut to 11 Nm (97 In. lbs.).
34. Connect the field circuit connector (3) to the generator.
35. Connect the right exhaust variable valve timing solenoid electrical connector (5).
36. Connect the right intake variable valve timing solenoid electrical connector (6).
37. Engage the wire harness retainers (1 and 4) to the right cylinder head cover.
38. Connect three fuel injector electrical connectors (5).
39. Connect three ignition coil electrical connectors (2).
40. Connect the electrical connector (4) to the right Camshaft Position (CMP) sensor.
41. Connect the main harness to the engine injection/ignition harness (1).
42. Engage three main wire harness retainers (3) to the right cylinder head cover.
43. Connect the right upstream oxygen sensor (1) and the right downstream oxygen sensor (2) electrical connectors.
44. Secure the main wire harness retainer to the rear of the right cylinder head with the bolt (1) tightened to 12 Nm (106 in. lbs.).
45. Connect the electrical connector (2) to the ignition coil capacitor.
46. Position the power steering pump (with bracket) and install the upper power steering pump bracket retaining bolts (3). Do not tighten at this time.
47. Engage the wiring harness routing retainer (2) to the power steering pump bracket.
48. Raise and support the vehicle Maintenance.
49. Engage the wiring harness routing retainer (3) to the power steering pump bracket (1).
50. Install the lower power steering pump retaining bolt (2) and tighten all three retaining bolts to 24 Nm (18 ft. lbs.).
51. Install the accessory drive belt Engine - Installation.
52. Install the oil level indicator (1) with the bolt (2) tightened to 12 Nm (106 in. lbs.).
53. Connect the oil pump solenoid electrical connector (1).
54. Engage one wire harness retainer (2) to the engine block, one wire harness retainer (3) to the power steering pump mounting bracket and one wire harness retainer (4) to the right engine mount.
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55. Install the ground strap (1) with bolt (2) tightened to 12 Nm (106 in. lbs.).
56. Connect the main wire harness to the Crankshaft Position (CKP) sensor (5).
57. Engage one main wire harness retainer (4) to the engine block and one main wire harness retainer (3) to the oil level indicator.
58. Install the PCV hose (1) to the PCV valve (2).
59. Connect the fuel supply hose (2) to the fuel rail Service and Repair
60. Install the insulator (2) to the two alignment posts (3) on top of the LH cylinder head cover.
61. Install the upper intake manifold and insulator Intake Manifold - Installation
62. Position the heater core tube assembly and install the heater core supply hose (2), heater core return hose (1) and oil cooler return hose (4).
63. Secure the heater core tube assembly to the right upper intake manifold support bracket with two nuts (3) tightened to 12 Nm (106 in. lbs.).
64. Connect the heater core supply hose (1) to the heater core tube assembly.
65. Connect the heater core return hose (2) to the heater core tube assembly.
66. Install the lower radiator hose (3) to the engine coolant pump housing.
67. Install the upper radiator hose (1) to the engine thermostat housing.
68. Install the battery tray (4), Totally Integrated Power Module (TIPM) and battery Battery Tray - Installation.
69. Install the front wheelhouse inner splash shields Splash Shield - Installation.
70. If equipped with a manual transmission, install the shift lever (2) Service and Repair.
71. Install the air cleaner body (1) Air Cleaner Body - Installation.
72. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level Service and Repair
73. Fill the cooling system Service and Repair.
74. Install the engine cover (1).
75. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.).
76. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level Service and Repair
NOTE: The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components.