- Lay the engine wiring
harness on to the engine.
- Connect the following engine wiring harness electrical connectors:
- Install the vacuum hose
(2) to the tee on the rear vacuum port.
- Connect the MAP sensor electrical connector (1).
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or
corrosion inhibitors on fasteners or fastener joint surfaces unless specified.
These coatings affect fastener torque and joint clamping force and may damage
the fastener. Use the correct tightening sequence and specifications when
installing fasteners in order to avoid damage to parts and systems.
- Install the engine wiring harness clip bolt (3).
Tighten
Tighten the engine wiring harness clip bolt to 50 N·m (37 lb ft).
- Connect the following
engine wiring harness electrical connectors:
• | Oil pressure sensor (1) |
• | Knock sensor harness (4) |
- Install engine wiring harness ground bolts (2, 3).
Tighten
Tighten the engine wiring harness ground bolts to 50 N·m
(37 lb ft).
- Connect the following
engine wiring harness electrical connectors:
- Install the rosebud clips (3) to the fuel rail.
- Connect the CPA retainer (1).
- Connect the following
engine wiring harness electrical connectors:
• | Canister purge valve (5) |
- Install the rosebud clips (4) to the fuel rail.
- Connect the CPA retainer (1).
- Install the right catalytic
converter gasket (2) and converter.
- Install the exhaust manifold pipe nuts (1).
Tighten
Tighten the exhaust manifold pipe nuts to 35 N·m (26 lb ft).
- Install the left catalytic
converter gasket (2) and converter.
- Install the exhaust manifold pipe nuts (1).
Tighten
Tighten the exhaust manifold pipe nuts to 35 N·m (26 lb ft).
- Install the J 41798
to the engine block.
- Install a engine hoist to the engine block.
- Remove the engine from the engine stand.
- Install the manual transmission
flywheel, if equipped.
- Install the automatic
transmission flywheel, if equipped.
- Install the engine flywheel bolts.
Tighten
- Tighten the engine flywheel bolts a first pass in sequence to
20 N·m (26 lb ft).
- Tighten the engine flywheel bolts a second pass in sequence to
50 N·m (37 lb ft).
- Tighten the engine flywheel bolts a final pass in sequence to
100 N·m (74 lb ft).
- Install the clutch disc
and pressure plate to the flywheel, if equipped.
- Install the pressure plate bolts until snug, if equipped.
- Using J 38836
,
align the clutch disc splines with the pilot bearing.
- Tighten the clutch pressure
plate bolts.
Tighten
Tighten the clutch pressure plate bolts in sequence (as shown) and evenly
over 3 increments with the fourth increment to 70 N·m (52 lb ft).
- Remove the J 38836
.
- Remove the J 21366
from the automatic transmission.
- Mate the transmission to the engine.
- Install the manual transmission
bolts (2), if equipped.
Tighten
Tighten the manual transmission bolts to 50 N·m (37 lb ft).
- Install the automatic
transmission bolts, if equipped.
Tighten
Tighten the automatic transmission bolts to 95 N·m (70 lb ft).
- Remove the support from the transmission on the J 39580
.
- With the aide of an assistant, position the engine and transmission
over the crossmember.
- Lower the engine using the J 41798
.
- Install the left side
engine mount and studs.
Tighten
Tighten the engine mount studs to 50 N·m (37 lb ft).
- Install the engine mount
heat shield and nuts.
Tighten
Tighten the engine mount heat shield nuts to 10 N·m (89 lb in).
- Install the right side
engine mount and bolts.
Tighten
Tighten the engine mount bolts to 50 N·m (37 lb ft).
- Remove the engine hoist from the J 41798
.
- Install the generator.
- Install the transmission oil cooler clip and generator bolts until
snug.
- Install the generator
rear bracket bolt (1) until snug.
- Tighten the generator bolts.
Tighten
• | Tighten the generator rear bracket bolt to 25 N·m
(18 lb ft). |
• | Tighten the generator bolts to 50 N·m (37 lb ft). |
- Install the push-in retainer
(4) to the manual transmission tab.
- Connect the following electrical connectors to the left side of
the manual transmission, if equipped:
• | Skip shift solenoid (1) |
• | Reverse lockout solenoid (2) |
• | Vehicle speed sensor (3) |
- Install the rosebud clip
(1) to the right side of the manual transmission, if equipped.
- Connect the back-up lamp switch electrical connector (2).
- Install the automatic transmission fill tube bolt.
Tighten
Tighten the automatic transmission fill tube bolt to 50 N·m
(37 lb ft).
- Install the engine wiring
harness clip bolt (1) to the automatic transmission, if equipped.
Tighten
Tighten the engine wiring harness clip bolt to 2.5 N·m
(22 lb in).
- Connect the following electrical connectors to the automatic transmission,
if equipped:
• | Vehicle speed sensor (3) |
- Install the torque converter
bolts.
Tighten
Tighten the torque converter bolts to 63 N·m (47 lb ft).
- Install the right transmission
cover and bolt, if equipped.
Tighten
Tighten the transmission cover bolt to 12 N·m (106 lb in).
- Install the left transmission
cover and bolt, if equipped.
Tighten
Tighten the transmission cover bolt to 12 N·m (106 lb in).
- Install the A/C compressor
bracket.
- Install the A/C compressor bracket bolts.
Tighten
Tighten the A/C compressor bolts to 50 N·m (37 lb ft).
- Install the A/C compressor.
- Install the A/C compressor bolts.
Tighten
Tighten the A/C compressor bolts to 50 N·m (37 lb ft).
- Connect the A/C compressor
electrical connector.
- Install the rosebud clip to the engine bracket.
- Install the power steering
pump bracket and bolts.
Tighten
Tighten the power steering pump bracket bolts to 50 N·m
(37 lb ft).
- Position the power steering
pump to the engine.
- Install the power steering pump brace (3) and bolts (4) to the
pump (1).
Tighten
Tighten the power steering pump bolts to 25 N·m (18 lb ft).
- Using J 25033-C
install the power steering pump pulley
(1).
- Install the A/C drive
belt around the crankshaft balancer.
- Install a ratchet with hex-head socket to the A/C belt tensioner
bolt.
- Rotate the A/C drive belt tensioner clockwise in order to relieve
tension on the drive belt tensioner.
- Install the A/C drive belt under the idler pulley.
- Install the A/C drive belt over the A/C compressor pulley.
- Slowly release tension on the A/C drive belt tensioner.
- Remove the ratchet and socket from the A/C drive belt tensioner
bolt.
- Route the accessory drive
belt around all the pulleys except the water pump pulley and tensioner.
- Install a ratchet with hex-head socket to the drive belt tensioner
bolt.
- Rotate the drive belt tensioner clockwise in order to relieve
tension on the accessory drive belt tensioner.
- Install the accessory drive belt under the water pump pulley.
- Install the accessory drive belt onto the drive belt tensioner.
- Slowly release the tension.
- Remove the ratchet and socket from the drive belt tensioner bolt.
- Remove the J 41798
from the engine.
- Install the ignition coil(s) (as required). Refer to
Ignition Coil Replacement
in Engine Controls
- 5.7L.
- Ensure that the crossmember is still secured to the J 39580
.
- Carefully lower the vehicle onto the engine and transmission assembly.
- Install the transmission
crossmember bolts.
Tighten
Tighten the transmission support bolts to 57 N·m (42 lb ft).
- Install the front crossmember
bolts.
Tighten
• | Tighten the four upper crossmember bolts to 125 N·m
(92 lb ft). |
• | Tighten the two lower crossmember bolts to 145 N·m
(107 lb ft). |
- Remove the security straps from the vehicle.
- Separate the engine wire harness branches.
- Raise the vehicle until the crossmember is off the J 39580
.
- Remove the J 39580
.
- Clip the brake lines to
the brake pipe clip.
- Close the fuel pipe clip (7).
- Install the front fuel pipe heat shield (2).
- Install the front fuel pipe heat shield nuts (1).
Tighten
Tighten the front fuel pipe heat shield nuts to 5 N·m (44 lb in).
- Unsecure both steering
knuckles.
- Install the left and right upper control arm nuts.
Tighten
Tighten the upper control arm nuts to 53 N·m (39 lb ft).
- Install new cotter pins.
- Install the right and
left side shock absorber lower bolts.
Tighten
Tighten the shock absorber bolts to 65 N·m (48 lb ft).
- Install the starter motor. Refer to
Starter Motor Replacement
in Engine Electrical.
- Install the positive lead
to the generator.
- Install the battery positive cable nut to the generator output
stud.
Tighten
Tighten the engine wiring harness generator output stud nut to 22 N·m
(16 lb ft).
- Position the generator output terminal boot over the terminal.
- Connect the left and right
side wheel speed sensor electrical connectors.
- Install the intermediate
steering shaft to the power steering rack.
- Install the intermediate steering shaft bolt.
Tighten
Tighten the intermediate steering shaft bolt to 47 N·m
(35 lb ft).
- Install the torque arm. Refer to
Torque Arm Replacement
in Rear Suspension.
- Install the propeller shaft. Refer to
One-Piece Propeller Shaft Replacement
in Propeller Shaft.
- Connect the master cylinder
hose to the clutch actuator hose, if equipped.
- Snap the automatic transmission
range selector lever cable to the bracket, if equipped.
- Install the automatic
transmission range selector lever cable retainer, if equipped.
- Snap the automatic transmission
range selector lever cable to the range selector lever, if equipped.
- Position the RF ground
strap and cruise control ground lead to the frame rail.
- Install the engine wiring harness ground bolt.
Tighten
Tighten the engine wiring harness ground bolt to 12 N·m
(106 lb in).
- Install the stabilizer
bar brackets.
- Install the stabilizer bar bracket bolts/stud.
Tighten
Tighten the stabilizer bar bracket bolts/stud to 55 N·m
(41 lb ft).
- Install the drive side front fascia air deflector. Refer to
Front Bumper Fascia Air Deflector Replacement
in Bumpers.
- Install the exhaust crossover pipe. Refer to
Exhaust Crossover Pipe Replacement
in Engine Exhaust.
- Connect ALL oxygen sensor electrical connectors.
- Install the front wheels. Refer to
Tire and Wheel Removal and Installation
in Tires and Wheels.
- Install the lower oil
cooler line to the radiator.
Tighten
Tighten the lower oil cooler line fitting to 27 N·m (20 lb ft).
- Lower the vehicle.
- Pull the engine wiring
harness through the front of dash.
- Connect the engine wiring
harness to the instrument panel wiring harness.
- Remove the hinge pillar trim panel. Refer to
Body Hinge Pillar Trim Panel Replacement
in Interior Trim.
- Remove the right side insulator panel. Refer to
Instrument Panel Insulator Panel Replacement - Right Side
in Instrument Panel,
Gages, and Console.
- Install the PCM to the
bracket.
- Connect the PCM connectors.
Tighten
Tighten the PCM connector bolts to 8 N·m (71 lb in).
- Connect the engine harness
vacuum tube to the bottom of the vacuum check valve.
- Connect the forward lamp harness to the engine harness.
- Connect the secondary captured locks.
- Install the front two brake lines to the brake pressure modulator
valve.
Tighten
Tighten the brake pipe fittings to 15 N·m (11 lb ft).
- Install the brake booster vacuum hose.
- Install the AIR hose (2)
to the AIR shut-off valve (1).
- Install and snap the accelerator
and cruise control cable to the throttle body bracket.
Caution: In order to avoid possible injury or vehicle damage, always replace
the accelerator control cable with a NEW cable whenever you remove the engine
from the vehicle.
In order to avoid cruise control cable damage, position the cable out
of the way while you remove or install the engine. Do not pry
or lean against the cruise control cable and do not kink the cable. You must
replace a damaged cable.
- Install the accelerator control cable to the throttle lever.
- Install the cruise control
cable to the throttle lever.
- Connect the fuel line
to the fuel rail.
- Connect the vapor line to the fuel vapor purge valve.
- Install the inlet and
outlet heater hoses to the water pump.
- Install the condenser
tube to the condenser.
- Install the air conditioning condenser tube nut.
Tighten
Tighten the air conditioning condenser tube nut to 16 N·m
(12 lb ft).
- Install the upper oil
cooler line to the radiator.
Tighten
Tighten the lower oil cooler line fitting to 27 N·m (20 lb ft).
- Install the A/C compressor
and condenser hose bolt at the accumulator.
Tighten
Tighten the A/C compressor and condenser hose bolt to 16 N·m
(12 lb ft).
- Install the shift control closeout boot, if equipped with a manual
transmission. Refer to
Shift Control Shift Closeout Boot Replacement
in Manual Transmission -MM6.
- Install the lower radiator (outlet) hose. Refer to
Radiator Outlet Hose Replacement
in Engine Cooling.
- Install the upper radiator (inlet) hose. Refer to
Radiator Inlet Hose Replacement
in Engine Cooling.
- Install the fan shroud. Refer to
Fan Shroud Replacement
in Engine Cooling.
- Connect the positive battery
cable.
Tighten
Tighten the positive battery cable fitting to 15 N·m (11 lb ft).
- Connect the negative battery cable. Refer to
Battery Negative Cable Disconnection and Connection
in Engine Electrical.
- Recharge the A/C system. Refer to
Refrigerant Recovery and Recharging
in Heating, Ventilation, and
Air Conditioning.
- Fill the crankcase with the proper quantity and grade of engine
oil. Refer to
Approximate Fluid Capacities
and
Fluid and Lubricant Recommendations
in
Maintenance and Lubrication.
- Disable the ignition system.
- Crank the engine several times. Listen for any unusual noises
or evidence that parts are binding.
- Enable the ignition system.
- Start the engine and listen for unusual noises.
- Check the vehicles oil pressure gage and confirm that the engine
has acceptable oil pressure.
- Run the engine speed at about 1,000 RPM until the engine
has reached normal operating temperature.
- Listen for sticking lifters and other unusual noises.
- Inspect for fuel, oil and/or coolant leaks while the engine is
running.
- Perform the crankshaft position (CKP) system variation learn procedure.
Refer to
Crankshaft Position System Variation Learn
in Engine Controls - 5.7L.
- Bleed the brake system. Refer to
Hydraulic Brake System Bleeding
in Hydraulic Brakes.
- Bleed the power steering system. Refer to
Power Steering System Bleeding
in Power Steering System.
- Bleed the clutch hydraulic system, if equipped. Refer to
Hydraulic Clutch Bleeding
in Clutch.
- Perform a final inspection for the proper engine oil and coolant
levels.