Installation
EngineSpecial Tool(s):
Material:
Installation
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
2. NOTE: The engine must be to the left of the center line to install.
Raise the engine high enough to clear the No. 1 crossmember and position the engine into the vehicle.
3. NOTE: Left side shown, right side similar.
Position the engine mounts in the vehicle.
4. Align the torque converter studs with the holes in the flywheel and push the engine in. Install the top engine-to-transmission bolts.
^ Tighten to 47 Nm (35 ft. lbs.).
5. Lower the engine until it is just above the motor mounts and install the 4 RH engine mount bolts.
^ Tighten to 80 Nm (59 ft. lbs.).
6. Install the 4 LH engine mount bolts.
^ Tighten to 80 Nm (59 ft. lbs.).
7. Remove the transmission jack.
8. Install a new O-ring seal on the oil pickup tube and position the oil pickup tube in the oil pan.
9. Install a new press-in-place gasket into the upper oil pan.
10. Position the oil pan in the vehicle.
11. Install the oil pickup tube and bolts.
^ Tighten to 13 Nm (10 ft. lbs.).
12. Position the oil pan and install the bolts.
1 Install the 5 longer oil pan bolts.
2 Install the remaining oil pan bolts.
^ Tighten to 13 Nm (10 ft. lbs.).
13. Clean and inspect the oil pan drain plug and gasket. Install new, if necessary.
14. Install the oil pan drain plug.
^ Tighten to 25 Nm (18 ft. lbs.).
15. Lower the engine into place and remove the special tools.
16. Install the factory engine lifting bracket.
17. Position the ground strap and install the bolt.
^ Tighten to 12 Nm (9 ft. lbs.).
18. Loosely install the turbocharger exhaust pipe.
19. NOTE: Remove the plug or cap as needed.
Install the injection control pressure (ICP) sensor.
^ Tighten to 12 Nm (9 ft. lbs.).
20. NOTE: Remove the protective covering from the cylinder head.
Install the LH valve cover gasket, valve cover and bolts.
^ Tighten to 9 Nm (80 inch lbs.).
21. Install the glow plug module mounting bracket and the nuts.
^ Tighten to 8 Nm (71 inch lbs.).
22. Install the glow plug module and the nuts.
^ Tighten to 8 Nm (71 inch lbs.).
23. Connect the exhaust pressure tube to the exhaust manifold.
^ Tighten to 30 Nm (22 ft. lbs.).
24. NOTE: Install a new O-ring seal and lubricate with clean engine oil prior to installation.
Position the oil indicator and tube, install the retaining nut and connect the glow plug wire retainer.
^ Tighten to 8 Nm (71 inch lbs.).
25. Position the fuel tubes and install the mounting bolts for the fuel tube bracket.
26. Install the lower engine-to-transmission bolts.
^ Tighten to 47 Nm (35 ft. lbs.).
27. NOTE: Left side shown, right side similar.
NOTE: The top retaining nut must be tightened first.
Install the 4 engine mount-to-crossmember nuts.
^ Tighten to 90 Nm (66 ft. lbs.).
28. Install the starter motor, stud bolt and bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
29. Connect the starter motor electrical connection.
^ Tighten to 14 Nm (10 ft. lbs.).
30. Connect the starter motor electrical connection.
^ Tighten to 6 Nm (53 inch lbs.).
31. Install the starter motor solenoid protective cap.
32. Position the battery cable bracket and install the nut.
^ Tighten to 22 Nm (16 ft. lbs.).
33. Connect the block heater electrical connector.
34. Install new torque converter nuts.
^ Tighten to 35 Nm (26 ft. lbs.).
35. Install the torque converter cover.
36. Connect the transmission tubes and install the retaining clips.
37. Position the transmission cooler tube support bracket on the stud and install the nut.
^ Tighten to 12 Nm (9 ft. lbs.).
38. Install the oil filter assembly and the bolts.
^ Tighten to 24 Nm (18 ft. lbs.).
39. Position the engine wiring harness and connect the powertrain control module (PCM) electrical connectors.
40. Connect the 2 engine-to-vehicle electrical connectors.
41. Connect the LH glow plug electrical connector.
42. Connect the push pin retainer and exhaust pressure sensor electrical connector.
43. Connect the electrical connector and wire retainers at the transmission.
44. Connect the glow plug module electrical connectors.
45. Connect the camshaft position sensor electrical connector and retaining clips.
46. Position the wiring and connect the glow plug and ICP sensor electrical connectors.
47. Connect the crankshaft position (CKP) sensor electrical connector and retaining clips.
48. Connect the fuel tube spring lock couplings and install the retaining clips. For additional information, refer to Fuel Delivery and Air Induction.
49. Install the lower radiator hose.
50. Position the power steering pump and install the 2 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
51. Install the LH fan stator stand-off.
^ Tighten to 47 Nm (35 ft. lbs.).
52. Install the 2 power steering upper mounting bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
53. NOTE: The bolt behind the pulley is accessed through the pulley with an extension and a short socket.
Position the vacuum pump and install the 3 bolts.
^ Tighten to 47 Nm (35 ft. lbs.).
54. Connect the vacuum pump hose and install the engine coolant fill hose clip.
55. Install the engine coolant fill hose, tighten the clamp and connect the engine fill hose into the retaining clip.
56. Install the idler pulley and bolt.
^ Tighten to 47 Nm (35 ft. lbs.).
57. Connect the heater hose.
58. Install the A/C compressor and the 3 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
59. NOTE: Remove the caps or plugs as needed. Install new O-ring seals and lubricate with PAG oil.
Connect the high-pressure switch electrical connector and install the A/C manifold at the T-block.
^ Tighten to 47 Nm (35 ft. lbs.).
60. Connect the A/C compressor electrical connector.
61. Position back the cable and install the bolt. Install the RH fan stator stand-off.
^ Tighten both to 47 Nm (35 ft. lbs.).
62. Install the intake manifold.
63. NOTE: LH shown, RH similar.
Install the lower radiator supports and bolts.
^ Tighten to 20 Nm (15 ft. lbs.).
64. NOTE: RH shown, LH similar.
Install the upper radiator supports and the 8 bolts.
^ Tighten to 20 Nm (15 ft. lbs.).
65. Position the hood latch and install the 2 bolts.
^ Tighten to 12 Nm (9 ft. lbs.).
66. Position the headlamp wiring harness, connect the air bag sensor and install the 2 bolts.
^ Tighten to 12 Nm (9 ft. lbs.).
67. Install the valance panel, radiator grille support and grille opening panel reinforcement.
68. Install the front bumper.
69. Install the A/C condenser assembly. Refer to Heating and Air Conditioning. and Air Conditioning
70. Fill the engine with clean engine oil.
71. Connect the battery ground cable. For additional information, refer to Battery.
72. Check and top off the transmission fluid level.