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Section 505 (5.7L Engine (Service Information)): Installation: Installation

WARNING: This page is about a different car, the 2016 Dodge Charger and 2015 Dodge Charger. However, it is still accessible from the selected car via links, so may be relevant.
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.

Fig 1: Engine Lift Fixture & Adapter
GC0081822Courtesy of CHRYSLER GROUP, LLC
NOTE:

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

  1. Install the engine lift fixture (special tool #8984B, 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. Automatic transmission equipped vehicles, 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.
    Fig 2: Engine Mount Heat Shield Retaining Nuts, Lower Mount Retaining Bolts & Heat Shields
    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 the proper specification. Refer to TORQUE SPECIFICATIONS  .
  7. Position both left and right engine mount heat shields (4), install the retaining nuts (3) and tighten to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  8. Remove the engine hoist and the jack supporting the transmission.
  9. Raise and support the vehicle.
    Fig 3: Removing/Installing Transmission
    GC0095569Courtesy of CHRYSLER GROUP, LLC
  10. Manual transmission equipped vehicles, install the transmission (Refer to appropriate MANUAL TRANSMISSION article ).
    Fig 4: Remove/Install Transmission To Oil Pan Bolts
    GC0080287Courtesy of CHRYSLER GROUP, LLC
  11. Automatic transmission equipped vehicles, Install the transmission to oil pan bolts (1) and tighten to the proper specification. Refer to TORQUE SPECIFICATIONS  .
    Fig 5: Remove/Install Transmission To Engine Bolts
    GC0082900Courtesy of CHRYSLER GROUP, LLC
  12. Install the remaining transmission bell housing to engine block bolts (2) and tighten to the proper specification. Refer to TORQUE SPECIFICATIONS  .
    Fig 6: Torque Converter Bolts
    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.

  13. Rotate the crankshaft in clockwise direction and install all six torque converter to flexplate bolts (1) finger tight.
  14. Verify that the torque converter is pulled flush to the flexplate and tighten bolts to the proper specification. Refer to TORQUE SPECIFICATIONS  .
    Fig 7: Remove/Install Torque Converter Access Cover
    GC0080285Courtesy of CHRYSLER GROUP, LLC
  15. Install the inspection cover (1) and tighten the retaining bolt (2) to the proper specification. Refer to TORQUE SPECIFICATIONS  .
    Fig 8: Crankshaft Position Sensor Electrical Connector
    GC0095565Courtesy of CHRYSLER GROUP, LLC
    NOTE: The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine block.
  16. Connect the Crankshaft Position Sensor (CKP) sensor wire harness connector (1).
  17. Install the starter. Refer to STARTER, INSTALLATION .
    Fig 9: Oxygen Sensor, Oxygen Sensor Connector, Ball Flange Nut & LH Catalytic Converter
    GC0080046Courtesy of CHRYSLER GROUP, LLC
  18. Position the catalytic converters (4) onto the exhaust manifold flanges, install the flange nuts (3) and tighten to the proper specification. Refer to SPECIFICATIONS .
  19. Connect the oxygen sensor (1) wire harness connectors (2).
    Fig 10: Knock Sensor, Electrical Connector & Bolt
    GC0144624Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Left side shown in illustration, right side similar.

  20. Connect the right and left knock sensor (1) wire harness connectors (5).
  21. Install the heat shields onto both knock sensors (shield snaps on/off sensor).
  22. If equipped, connect the transmission oil cooler lines to their retainers at the oil pan.
    Fig 11: Lower Radiator Hose
    GC0095212Courtesy of CHRYSLER GROUP, LLC
  23. Install the lower radiator hose (1).
  24. Lower the vehicle.
    Fig 12: Engine Lift Fixture & Adapter
    GC0080289Courtesy of CHRYSLER GROUP, LLC
  25. Remove the engine lift fixture (special tool #8984B, Fixture, Engine Lifting) (2) and adapter (special tool #8984-UPD, Adapter, Engine Lift) (4).
  26. Position the left and right side wiring harness.
    Fig 13: Oil Control Valve, Electrical Connector & Retaining Bolt
    GC0144407Courtesy of CHRYSLER GROUP, LLC
  27. Lubricate the Oil Control Valve (OCV) rubber O-ring seal with clean engine oil.
  28. Install the OCV (3) and rotate into position.
  29. Install the OCV retaining bolt (2) and tighten to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  30. Connect the OCV wire harness connector (1).
    Fig 14: Coolant Temperature (ECT) Sensor Electrical Connector, Heater Tube & Retaining Bolt
    GC0144611Courtesy of CHRYSLER GROUP, LLC
  31. Using a NEW  O-ring seal, install the heater core tube (3) into the water pump.
  32. Install the heater core tube retaining bolt (1) and tighten to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  33. Connect the Engine Coolant Temperature (ECT) sensor wire harness connector (2).
    Fig 15: Camshaft Position Sensor, Connector, Bolt & Timing Cover
    GC0095240Courtesy of CHRYSLER GROUP, LLC
  34. Connect the camshaft position sensor wire harness connector (4).
  35. Install the intake manifold. Refer to MANIFOLD, INTAKE, INSTALLATION, 5.7L  .
    Fig 16: Heater Hose Supply
    GC0095566Courtesy of CHRYSLER GROUP, LLC
  36. Connect the heater hoses (1, 2).
  37. Connect the ground wires to the rear of each cylinder head.
    Fig 17: Ignition Capacitor, Electrical Connector & Intake Manifold
    GC0080072Courtesy of CHRYSLER GROUP, LLC
    NOTE:

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

  38. Connect the ignition capacitor (2) wire harness connector (1).
    Fig 18: Oil Pressure Sensor Electrical Connector
    GC0095586Courtesy of CHRYSLER GROUP, LLC
  39. Connect the oil pressure sensor wire harness connector (1).
    Fig 19: Oil Temperature Sensor Electrical Connector
    GC0095588Courtesy of CHRYSLER GROUP, LLC
  40. Connect the oil temperature sensor wire harness connector.
  41. Raise and support the vehicle.
  42. Install the generator. Refer to GENERATOR, INSTALLATION .
  43. Install the A/C compressor. Refer to COMPRESSOR, A/C, REMOVAL .
    Fig 20: Lower Splash Shield & Fasteners
    GC0095584Courtesy of CHRYSLER GROUP, LLC
  44. Install the belly pan and securely tighten bolts (1).
  45. Remove support and lower the vehicle.
    Fig 21: Removing/Installing A/C Suction Front Line
    GC0081082Courtesy of CHRYSLER GROUP, LLC
  46. Position the front section of the A/C suction line (2) into the engine compartment.
  47. 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 system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

  48. 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 system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
  49. Connect the front section of the A/C suction line to the rear section of the A/C suction line.
  50. 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 the proper specification. Refer to SPECIFICATIONS .
    Fig 22: Removing/Installing A/C Liquid Front Line
    GC0081079Courtesy of CHRYSLER GROUP, LLC
  51. Position the front section of the A/C liquid line into the engine compartment.
  52. 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 system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

  53. 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 system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
  54. Connect the front section of the A/C liquid line to the rear section of the A/C liquid line.
  55. 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 the proper specification. Refer to SPECIFICATIONS .
    Fig 23: Ignition Coil Mounting Bolts
    GC0080075Courtesy of CHRYSLER GROUP, LLC
  56. Position the ignition coil wire harness and connect all ignition coil wire harness connectors (1).
    Fig 24: Coolant Recovery Container Pressure Cap, Tube & Screws
    GC0144485Courtesy of CHRYSLER GROUP, LLC
  57. Install the pressurized coolant bottle (1). Tighten the bolts (2) the proper specification. Refer to SPECIFICATIONS .
  58. Position the wire harness and secure to the right hand inner fender panel.
  59. Install the cooling fan. Refer to FAN, COOLING, INSTALLATION .
    Fig 25: Radiator Fan Assembly
    GC0079911Courtesy of CHRYSLER GROUP, LLC
  60. Install the upper radiator hose (2).
    Fig 26: Removing/Installing Cowl Panel
    GC0080264Courtesy of CHRYSLER GROUP, LLC
  61. Install the strut tower support (6) and tighten bolts to the proper specification. Refer to TORQUE SPECIFICATIONS  .
  62. Install the cowl panel cover. Refer to COVER, COWL PANEL, INSTALLATION .
  63. Fill the crankcase with the specified type and amount of engine oil. Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
  64. Fill the cooling system with the specified type and amount of engine coolant. Refer to STANDARD PROCEDURE .
    Fig 27: Oil Fill Cap & Engine Cover
    GC0143807Courtesy of CHRYSLER GROUP, LLC
  65. Install the engine cover (2).
  66. Connect the negative battery cable.
  67. Charge the Refrigerant System. Refer to PLUMBING, STANDARD PROCEDURE .
  68. 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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