- Remove the engine from the engine stand.
- Slowly install the engine into the engine compartment aligning the engine
mounts with the brackets.
- When the engine mounts are aligned, install the engine mounts, putting
the mount up through the engine mount brackets before inserting into the chassis
mount brackets.
Notice: Refer to Fastener Notice in the Preface section.
- Lower the engine onto the mounts and install the upper engine mount nuts.
Tighten
Tighten the nuts to 70 N·m (51 lb ft).
- Remove the engine hoist.
- Lay the radiator into the radiator support, but do not install the radiator
completely.
- Raise the vehicle. Refer to
Lifting and Jacking the Vehicle
in General Information.
- Install all of the lower bell housing bolts, excluding the top four.
- Remove the two through bolts securing the transmission support.
- Lower the transmission.
- Install the top four bell housing bolts.
Tighten
Tighten all eleven bell housing bolts to 50 N·m (37 lb ft).
- Raise the transmission.
- Install the transmission support. Refer to
Transmission Support Replacement
in Frame and Underbody.
- Install the 3 torque converter bolts.
Tighten
Tighten the torque converter bolts to 60 N·m (44 lb ft).
- Install the torque converter bolt cover.
- Install the fuel tank shield, if removed. Refer to
Fuel Tank Shield Replacement
in Frame and Underbody.
- Install the engine protection shield. Refer to
Engine Protection Shield Replacement
.
- Install the propeller shaft to the front axle pinion yoke. Refer to
Front Propeller Shaft Replacement
in Propeller Shaft.
- Connect the exhaust pipe to the manifold
and secure the pipe with the bolts.
Tighten
Tighten the exhaust pipe bolts to 50 N·m (37 lb ft).
- Connect the oil pressure sensor electrical connector.
- Install the oil pan drain plug.
Tighten
Tighten the plug to 26 N·m (19 lb ft).
- Install the lower radiator hose (1).
- Install the left and right wheel drive shafts. Refer to
Wheel Drive Shaft Replacement
in Wheel Drive Shafts.
- Lower the vehicle.
- Install the 4 grounds on the left side of
the block (1).
- Install the camshaft sensor electrical connectors.
- Install the crankshaft sensor electrical connector.
- Install the knock sensor electrical connector.
- Install the generator electrical connector
and battery lead (1).
Tighten
Tighten the generator battery lead nut to 9 N·m (80 lb in).
- Install the A/C pressure sensor and clutch electrical connector.
- Install starter electrical connectors and
battery lead (1).
Tighten
Tighten the starter battery lead to 9 N·m (80 lb in).
- Install the fuel lines at the fuel pressure regulator. Refer to
Fuel Pressure Regulator Replacement
in Engine Controls
- 4.2L.
- Install the engine harness bracket and bolt.
Tighten
Tighten the engine harness bracket bolt to 50 N·m (37 lb ft).
- Install the front differential vent hose, to the engine harness bracket.
- Install all the harnesses to the engine harness bracket.
- Install the PCM. Refer to
Powertrain Control Module Replacement
in Engine Controls - 4.2L.
- Install the power brake hose at booster
- Install the harness retainer (1)
to the original location.
- Install the ignition coil harness electrical connectors.
- Clip the transmission cooler lines to the
right side of the engine block.
- Connect the camshaft phaser actuator valve electrical connector.
- Connect the front axle actuator electrical connector.
- Connect the A/C line at the accumulator.
- Install the oxygen sensor electrical connector.
- Remove the lift hook J 44220
.
- Install the AIR adapter and secure the adapter
with the studs.
Tighten
Tighten the AIR adapter studs to 25 N·m (18 lb ft).
- Install the transmission filler tube bracket
to AIR adapter stud and secure the bracket with the nut.
Tighten
Tighten the nut to 10 N·m (89 lb in).
- Install the heater hoses to the heater core. Refer to
Heater Inlet Hose Replacement
and
Heater Outlet Hose Replacement
in Heating, Ventilation, and Air Conditioning.
- Install the power steering pump.
- Install the power steering pump bolts.
Tighten
Tighten the bolts to 25 N·m (18 lb ft).
- Install the drive belt. Refer to
Drive Belt Replacement
.
- Install cooling fan and shroud, tilting the radiator forward for clearance.
- Finish installing the radiator. Refer to
Radiator Replacement
in Engine Cooling.
- Install transmission cooler lines together.
- Install map Sensor. Refer to
Manifold Absolute Pressure Sensor Replacement
in Engine Controls - 4.2L.
- Install the throttle body. Refer to
Throttle Body Assembly Replacement
in Engine Controls - 4.2L.
- Install the hood latch. Refer to
Hood Latch Support Replacement
in Body Front End.
- Install the head lamp housing. Refer to
Headlamp Housing Panel Replacement
in Body Front End.
- Install the grill. Refer to
Grille Replacement
in Exterior Trim.
- Install the washer solvent container. Refer to
Windshield Washer Solvent Container Replacement
in Wipers/Washer Systems.
- Install the air cleaner assembly. Refer to
Air Cleaner Assembly Replacement
in Engine Controls - 4.2L.
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine Electrical.
- Install the hood. Refer to
Hood Replacement
in Body Front End.
- Service the engine oil.
- Fill the cooling system. Refer to
Cooling System Draining and Filling
in Engine Cooling.
- Recharge the refrigerant. Refer to
Refrigerant Recovery and Recharging
in Heating, Ventilation and Air Conditioning.
- Perform the CKP system variation learn procedure. Refer to
Crankshaft Position System Variation Learn
in Engine Controls
- 4.2L.
| Important: After an overhaul, the engine should be tested. Use the following procedure
after the engine is installed in the vehicle.
|
• | Disable the ignition system. |
• | Crank the engine several times. Listen for unusual noises or evidence
that parts are binding. |
• | Enable the ignition system. |
• | Start the engine and listen for unusual noises. |
• | Check the vehicle oil pressure gage or light and confirm that the engine
has acceptable oil pressure. |
• | Run the engine speed at about 1000 RPM until the engine has reached
normal operating temperature. |
• | Listen for a sticking lifter and other unusual noises. |
• | Inspect for fuel, oil and/or coolant leaks while the engine is running. |
• | Perform a final inspection for the proper engine oil and coolant levels. |
- Install the hood. Refer to
Hood Replacement
in Body Front End.