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Installation - Engine Assembly

WARNING: This page is about a different variant/trim than selected.
CAUTION: Care must be taken when installing the engine to prevent pinching the power steering rack sensor with the left engine mount.
Fig 1: ENGINE LIFTING BRACKET #8534
GC0015405Courtesy of DAIMLERCHRYSLER CORP.
1 - LIFTING CHAIN
2 - ENGINE LIFTING BRACKET #8534
3 - CAM POSITION SENSOR
4 - EGR VALVE
5 - BOLTS
6 - COOLANT PIPE
  1. Install special tool #8534B, engine lifting bracket (2) to the right rear of the cylinder head and install a bolt into the inner most bolt hole (5) next to the bracket (5). See Fig 1.
    Fig 2: ENGINE LIFTING POINT
    GC0015404Courtesy of DAIMLERCHRYSLER CORP.
    1 - LIFTING CHAIN
    2 - UPPER TIMING CHAIN COVER
    3 - POWER STEERING PUMP
    4 - THERMOSTAT HOUSING
  2. Connect a engine hoisting chain (1) to the left timing chain cover (2) lifting point and the engine lifting bracket. See Fig 2.
    Fig 3: TRANSMISSION MOUNTING
    GC0012851Courtesy of DAIMLERCHRYSLER CORP.
    1 - ENGINE
    2 - BOLTS
    3 - TRANSMISSION
    CAUTION: Care must be taken when installing the engine to prevent pinching the power steering rack sensor with the left engine mount. Constantly check to assure proper positioning and no damage occurs to other components or harnesses until union is made.
    NOTE: As the engine is lowered into the engine bay area, install and hand tighten the A/C compressor bolt retaining the transmission cooler lines.
  3. Carefully install the engine into the engine bay area and complete the union with the transmission.
  4. Properly route the engine wiring harness behind the engine and tighten the accessible transmission bolts to 68N.m (50 ft.lbs.). See Fig 3
    Fig 4: IGNITION COILS - RIGHT CYLINDER HEAD
    GC0015400Courtesy of DAIMLERCHRYSLER CORP.
    1 - FUEL RAIL
    2 - IGNITION COIL
    3 - CAPACITOR
    4 - ENGINE WIRING HARNESS
  5. Properly position the right engine harness (4) and connect the oxygen sensor, knock sensor, EGR, fuel injector and ignition coil harness connectors. See Fig 4.
  6. Connect the capacitor (3) and ground strap (3) to the right cylinder head cover.
  7. Install the right intake manifold support braces.
    Fig 5: IGNITION COILS - LEFT CYLINDER HEAD
    GC0015401Courtesy of DAIMLERCHRYSLER CORP.
    1 - FUEL RAIL
    2 - IGNITION COILS
    3 - WIRING HARNESS
    4 - LOWER INTAKE MANIFOLD
  8. Properly position the left engine harness (3) and connect the ignition coil (2) and fuel injector harness connectors. See Fig 5.
  9. Connect the coolant temperature, cam position, oil pressure sensor harness connectors.
  10. Connect the oxygen sensor, and the ground wire, to the left cylinder head cover.
    Fig 6: COOLANT PIPE
    GC0015399Courtesy of DAIMLERCHRYSLER CORP.
    1 - COOLANT PIPE
    2 - HEATER HOSE
    3 - COOLANT RESERVOIR HOSE
  11. Connect the heater hose (2) and coolant reservoir hose (3) to the rear coolant pipe (1). See Fig 6.
  12. Install the upper intake manifold (Refer to MANIFOLD - INTAKE ).
  13. Connect the upper radiator hose.
    Fig 7: TRANSMISSION MOUNTING
    GC0012851Courtesy of DAIMLERCHRYSLER CORP.
    1 - ENGINE
    2 - BOLTS
    3 - TRANSMISSION
  14. Raise and support the vehicle.
  15. Install the engine mounting nuts and tighten to 101 N.m (75 lbs.ft.).
  16. Install the remaining transmission housing bolts and tighten to 68 N.m (50 ft.lbs.). See Fig 7
    Fig 8: FLYWHEEL BOLTS
    GC0015406Courtesy of DAIMLERCHRYSLER CORP.
    1 - OIL PAN
    2 - FLYWHEEL
    3 - BOLT
    4 - CRADLE
  17. Install the torque converter bolts (3). Tighten bolts to 75 N.m (55 lbs.ft.). See Fig 8.
  18. Install the torque converter inspection cover. Tighten bolts to 12 N.m (105 lbs. in.)
    Fig 9: RIGHT EXHAUST PIPE TO MANIFOLD UNION
    GC0015402Courtesy of DAIMLERCHRYSLER CORP.
    1 - EXHAUST UNION
    2 - HO2S - #2
  19. Connect the right exhaust pipe to the exhaust manifold (1) and connect the oxygen sensor (2). See Fig 9.
    Fig 10: FRONT DRIVE AXLE ASSEMBLY
    GC0015407Courtesy of DAIMLERCHRYSLER CORP.
    1 - LEFT FRONT DRIVE AXLE
    2 - INTERMEDIATE SHAFT
    3 - OIL PAN
    4 - FRONT DRIVE AXLE HOUSING
  20. Install the front drive axle housing and front axle shafts (if equipped with AWD). See Fig 10.
    Fig 11: LEFT EXHAUST PIPE TO MANIFOLD UNION
    GC0015403Courtesy of DAIMLERCHRYSLER CORP.
    1 - HO2S #1
    2 - EXHAUST UNION
    3 - HO2S-#2
  21. Connect the left exhaust pipe to the exhaust manifold (2) and connect the oxygen sensor (3). See Fig 11
  22. Install the crankshaft position sensor (Refer to FUEL SYSTEM/FUEL INJECTION/CRANKSHAFT POSITION SENSOR - INSTALLATION) .
    Fig 12: ENGINE BLOCK HEATER
    GC0015398Courtesy of DAIMLERCHRYSLER CORP.
    1 - NEGATIVE BATTERY CABLE
    2 - NEGATIVE BATTERY CABLE
    3 - BLOCK HEATER HARNESS
    4 - ENGINE BLOCK HEATER
  23. Connect the engine block heater (4) (if equipped). See Fig 12.
  24. Connect the ground strap (3) at the right transmission housing.
    Fig 13: RADIATOR HOSES
    GC0015396Courtesy of DAIMLERCHRYSLER CORP.
    1 - UPPER RADIATOR HOSE
    2 - LOWER RADIATOR HOSE
    3 - ENGINE OIL COOLER
    4 - COOLANT MODULE
  25. Tighten the transmission line bracket at the A/C compressor.
  26. Connect the oil cooler hose at the cooler (3) and secure the cooler hose retainer at the transmission. See Fig 13.
  27. Connect the lower radiator hose (2).
  28. Install the starter and spacer plate (Refer to ELECTRICAL/STARTING/STARTER MOTOR - INSTALLATION) .
    Fig 14: STEERING KNUCKLE
    GC0015397Courtesy of DAIMLERCHRYSLER CORP.
    1 - STEERING COUPLER
    2 - CRADLE
    3 - STEERING GEAR
    4 - BOLT
  29. Align and connect the steering column coupler (1) to the steering gear (3). See Fig 14.
  30. Connect the generator electrical connectors (Refer to ELECTRICAL/CHARGING/GENERATOR - INSTALLATION) .
  31. Install new oil filter.
  32. Install the lower engine close out panel.
  33. Lower the vehicle.
  34. Fill the cooling system to the proper level using the appropriate coolant (Refer to STANDARD PROCEDURE ).
  35. Fill engine crankcase with proper oil to correct level (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - SPECIFICATIONS) .
  36. Evacuate and recharge air conditioning.
  37. Install the windshield wiper cowl assembly.
  38. Install the hood.
  39. Connect the negative battery cable.
  40. Start engine and run until operating temperature is reached and radiator fans cycle.
  41. Check all fluid levels and properly fill.
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