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Section 720 (5.7L Engine (Service Information)): Installation

WARNING: This page is about a different car, the 2020 Chrysler 300 and 2019 Chrysler 300. However, it is still accessible from the selected car via links, so may be relevant.
NOTE:

New or remanufactured engines may come with the pilot bushing installed for the 8-speed transmissions. If the 8-speed pilot bushing is not needed it must be removed before engine installation.

CAUTION:

If the original engine has experienced a catastrophic failure or an individual failure with the piston, cylinder bore, engine block, valve or valve seat, the intake manifold MUST be replaced with a new manifold.

GC0081822Courtesy of CHRYSLER GROUP, LLC
NOTE:

Do not use air tools to install Engine Lift Fixture and Adapter (special tool #8984C, Fixture, Engine Lifting) (2, 3).

  1. Install the engine lift fixture (special tool #8984C, Fixture, Engine Lifting) (2) and adapter (special tool #8984-UPD, Adapter, Engine Lift) (4).
  2. Using a suitable engine hoist, lower the engine into in the engine compartment.
  3. Align the engine with the transmission.
  4. Install two transmission to engine block mounting bolts finger tight.
  5. Lower the engine assembly until the engine mounts rest in the engine cradle crossmember.
    GC0144614Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Left side shown in illustration, right side similar.

  6. Align the engine mounts, install both left and right engine mount to frame retaining bolts (2) and tighten to 68 N.m (50 ft. lbs.).
  7. Position both left and right engine mount heat shields (4), install the retaining nuts (3) and tighten to 27 N.m (20 ft. lbs.).
  8. Remove the engine hoist and the jack supporting the transmission.
  9. Raise and support the vehicle.
    GC0080287Courtesy of CHRYSLER GROUP, LLC
  10. Install the transmission to oil pan bolts (1) and tighten to 54 N.m (40 ft. lbs.).
    GC0082900Courtesy of CHRYSLER GROUP, LLC
  11. Install the remaining transmission bell housing to engine block bolts (2) and tighten to 68 N.m (50 ft. lbs.).
    GC0095570Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    It is essential that the correct length bolts are used to attach the converter to the flexplate. Bolts that are too long will damage the clutch surface inside the torque converter.

  12. Rotate the crankshaft in clockwise direction and install all torque converter to flexplate bolts (1) finger tight.
  13. Verify that the torque converter is pulled flush to the flexplate and tighten bolts to 88 N.m (65 ft. lbs.).
    GC0080285Courtesy of CHRYSLER GROUP, LLC
  14. Install the inspection cover (1) and tighten the retaining bolt (2) to 11 N.m (8 ft. lbs.).
    GC0095565Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The Crankshaft Position (CKP) sensor is located at the right rear side of the engine block.

  15. Connect the CKP sensor electrical connector (1).
    GC0080284Courtesy of CHRYSLER GROUP, LLC
  16. Position the starter motor (1) into the transmission.
  17. Install the three starter motor retaining bolts (2) and tighten to 54 N.m (40 ft. lbs.).
  18. Connect the solenoid wire to the starter motor (snaps in place).
  19. Position the battery cable to the solenoid stud, install the battery cable eyelet nut and tighten to 11 N.m (8 ft. lbs.).
  20. Position the starter heat shield (4) and install the retaining nuts (3).
  21. If equipped with AWD, install the front axle assembly. Refer to INSTALLATION .
    GC0080046Courtesy of CHRYSLER GROUP, LLC
  22. Position the catalytic converters (4) onto the exhaust manifold flanges, install the flange nuts (3) and tighten to 41 N.m (30 ft. lbs.).
  23. Connect the oxygen sensor electrical connectors (2).
    GC0144624Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Left side shown in illustration, right side similar.

  24. Connect the right and left knock sensor (1) electrical connectors (5).
  25. Install the heat shields onto both knock sensors (shield snaps on/off sensor).
  26. Connect the transmission oil cooler lines to their retainers at the oil pan.
    GC0095212Courtesy of CHRYSLER GROUP, LLC
    1 - LOWER RADIATOR HOSE
    2 - RADIATOR FAN ASSEMBLY
  27. Install the lower radiator hose (1).
  28. Lower the vehicle.
    GC0080289Courtesy of CHRYSLER GROUP, LLC
  29. Remove the engine lift fixture (special tool #8984C, Fixture, Engine Lifting) (2) and adapter (special tool #8984-UPD, Adapter, Engine Lift) (4).
  30. Position the left and right side wiring harness.
    GC0144407Courtesy of CHRYSLER GROUP, LLC
  31. Lubricate the oil control valve (OCV) rubber O-ring seal with clean engine oil.
  32. Install the OCV (3) and rotate into position.
  33. Install the OCV retaining bolt (2) and tighten to 11 N.m (8 ft. lbs.).
  34. Connect the OCV electrical connector (1).
    GC0144611Courtesy of CHRYSLER GROUP, LLC
  35. Install the heater core tube (3) into the water pump.
  36. Install the heater core tube retaining bolt (1) and tighten to 11 N.m (8 ft. lbs.).
  37. Connect the electrical connector to the coolant temperature (ECT) sensor (2).
    GC0095240Courtesy of CHRYSLER GROUP, LLC
  38. Connect the camshaft position sensor electrical connector (4).
    Fig 1: Intake Manifold Bolts Tightening Sequence
    GC0095568Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Install the intake manifold and throttle body as an assembly.

  39. Install the intake manifold. Refer to INSTALLATION  .
    GC0095566Courtesy of CHRYSLER GROUP, LLC
  40. Connect the heater hoses (1, 2).
  41. Connect the ground wires to the rear of each cylinder head.
    GC0080072Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The ignition capacitor (2) is attached to the rear of the left cylinder head.

  42. Connect the ignition capacitor (2) electrical connector (1).
    GC0095586Courtesy of CHRYSLER GROUP, LLC
  43. Connect the oil pressure sensor electrical connector (1).
  44. Connect the oil temperature sensor electrical connector.
    GC0081823Courtesy of CHRYSLER GROUP, LLC
  45. Position the generator (2) and install two generator mounting bolts (1) finger tight.
  46. Raise and support the vehicle.
    GC0144621Courtesy of CHRYSLER GROUP, LLC
  47. Position the generator support bracket (3) to the engine mount, install the retaining nut (1) finger tight.
  48. Position the generator support bracket (3) to the generator, install the retaining bolt (2) and tighten to 65 N.m (48 ft. lbs.).
  49. Tighten the generator support bracket (3) to engine mount retaining nut (1) to 28 N.m (21 ft. lbs.).
    GC0095564Courtesy of CHRYSLER GROUP, LLC
  50. Install the A/C compressor (3). Refer to COMPRESSOR, A/C, REMOVAL .
    GC0095584Courtesy of CHRYSLER GROUP, LLC
  51. Position the belly pan and install the belly pan retainers (1).
  52. Lower the vehicle.
    GC0081823Courtesy of CHRYSLER GROUP, LLC
  53. Tighten two generator mounting bolts (1) to 65 N.m (48 ft. lbs.).
  54. Snap the field wire connector into the rear of the generator.
  55. Position the generator B+ terminal eyelet to the generator output stud, install the retaining nut and tighten to 13 N.m (10 ft. lbs.).
  56. Snap the plastic insulator cap onto the B+ output terminal.
    GC0081082Courtesy of CHRYSLER GROUP, LLC
  57. Position the front section of the A/C suction line (2) into the engine compartment.
  58. Remove the tape or plugs from the fittings that connect the front section of the A/C suction line to the rear section of the A/C suction line (3).
    NOTE:

    Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

  59. Lubricate a new dual plane seal with clean refrigerant oil and install it onto the suction line fitting. Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
  60. Connect the front section of the A/C suction line to the rear section of the A/C suction line.
  61. Install the nut (1) that secures the front section of the A/C suction line to the rear section of the A/C suction line and tighten the nut to 22 N.m (16 ft. lbs.).
    GC0081079Courtesy of CHRYSLER GROUP, LLC
  62. Position the front section of the A/C liquid line into the engine compartment.
  63. Remove the tape or plugs from the fittings that connect the front section of the A/C liquid line to the rear section of the A/C liquid line (3).
    NOTE:

    Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

  64. Lubricate a new dual plane seal with clean refrigerant oil and install it onto the liquid line fitting. Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
  65. Connect the front section of the A/C liquid line to the rear section of the A/C liquid line.
  66. Install the nut (1) that secures the front section of the A/C liquid line to the rear section of the A/C liquid line and tighten the nut to 22 N.m (16 ft. lbs.).
    GC0080075Courtesy of CHRYSLER GROUP, LLC
  67. Position the ignition coil electrical harness and connect all ignition coil electrical connectors (1).
    GC0144485Courtesy of CHRYSLER GROUP, LLC
  68. Position the coolant bottle (1) and install the coolant bottle retaining bolts (2).
    GC0081538Courtesy of CHRYSLER GROUP, LLC
  69. Install the Power Distribution Center (PDC) and mounting bracket.
  70. Position the wire harness and secure to the right hand inner fender panel.
    GC0144483Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    Do not let the tensioner arm snap back to the freearm position, severe damage may occur to the tensioner.

  71. Rotate the accessory drive belt tensioner (8) clockwise until it contacts the stop and install the accessory drive belt (2) onto the pulleys, then slowly release the tensioner.
    GC0144321Courtesy of CHRYSLER GROUP, LLC
  72. Install the cooling fan. Refer to FAN, COOLING, INSTALLATION, 5.7/6.4L SINGLE FAN .
    GC0079911Courtesy of CHRYSLER GROUP, LLC
    1 - UPPER RADIATOR CLOSURE PANELS
    2 - UPPER RADIATOR HOSE
    3 - RADIATOR FAN ELECTRICAL CONNECTOR
    4 - RADIATOR FAN ASSEMBLY
  73. Install the upper radiator hose (2).
    GC0080264Courtesy of CHRYSLER GROUP, LLC
  74. Install the strut tower support (6) and tighten bolts to 38 N.m (28 ft. lbs.).
  75. Install the cowl panel cover (1). Refer to COVER, COWL PANEL, INSTALLATION .
  76. Fill the crankcase with the specified type and amount of engine oil. Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
  77. Fill the cooling system with the specified type and amount of engine coolant. Refer to STANDARD PROCEDURE .
    GC0143807Courtesy of CHRYSLER GROUP, LLC
  78. Position the engine cover (2) and secure the retaining grommets onto the ball studs.
    GC0139402Courtesy of CHRYSLER GROUP, LLC
  79. Connect the negative battery cable and tighten nut (1) to 5 N.m (45 in. lbs.).
  80. Perform the Refrigerant System Charge procedure. Refer to R-1234YF REFRIGERANT SYSTEM CHARGE .
  81. Start the engine and check for leaks.
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.

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