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Section 3 (5.7L Engine (Service Information)): Installation

WARNING: This page is about a different variant/trim than selected.
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.

GC0146152Courtesy of CHRYSLER GROUP, LLC
NOTE:

Do not use air tools to install Engine Lift Fixture (special tool #8984C, Fixture, Engine Lifting) (1).

  1. Install the Engine Lift Fixture (special tool #8984C, Fixture, Engine Lifting) (1).
  2. Connect a suitable engine lifting devise to the Engine Lift Fixture (special tool #8984C, Fixture, Engine Lifting) (1).
  3. Position the engine in the vehicle.
    GC0081756Courtesy of CHRYSLER GROUP, LLC
  4. Lower and align the engine (1) with the transmission (3).
  5. Continue to lower the engine assembly until the engine mounting brackets lineup with the engine mounts.
  6. Install two transmission to engine block mounting bolts (2) finger tight.
  7. Remove the engine lifting devise.
  8. Raise and support the vehicle.
    GC0146187Courtesy of CHRYSLER GROUP, LLC

    4x4 rear engine mount isolator shown, 4x2 rear engine mount isolator similar. 

  9. Using a suitable transmission hydraulic jack, slightly raise the transmission and remove the block of wood between the transmission and engine cradle crossmember, lower the transmission and remove the jack.
  10. Tighten the rear engine mount isolator retaining bolts (1) to the proper specifications. Refer to TORQUE SPECIFICATIONS  .
    GC0082900Courtesy of CHRYSLER GROUP, LLC
  11. Install the remaining transmission bell housing-to-engine block retaining bolts (2) and tighten to the proper specifications. Refer to TORQUE SPECIFICATIONS  .
    GC0146194Courtesy of CHRYSLER GROUP, LLC
  12. Install all torque converter-to-flexplate bolts (1) finger tight.
  13. Verify the torque converter is pulled flush to the flexplate and tighten bolts to the proper specifications. Refer to TORQUE SPECIFICATIONS  .
    GC0146153Courtesy of CHRYSLER GROUP, LLC

    Left side shown, right side similar. 

  14. Install the engine mount retaining nuts (2) and tighten to the proper specifications. Refer to TORQUE SPECIFICATIONS  .
    GC0145663Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    The structural dust cover must be installed as described in the following steps. Failure to do so may cause severe damage to the cover.

  15. Position the structural cover (2) in the vehicle.
  16. Install the structural dust cover bolts (1) to the engine block finger tight.
  17. Install the structural dust cover bolts (1) to the transmission finger tight.
    CAUTION:

    The structural dust cover must be held tightly against both the engine and the transmission bell housing during the tightening sequence. Failure to do so may cause severe damage to the cover.

  18. Tighten the structural dust cover bolts to the transmission to 9 N.m (80 in. lbs.).
  19. Tighten the structural dust cover bolts to the engine block to 9 N.m (80 in. lbs.).
  20. Again, tighten the structural dust cover bolts to the transmission to 54 N.m (40 ft. lbs.).
  21. Again, tighten the structural dust cover bolts to the engine block to 54 N.m (40 ft. lbs.).
    GC0146152Courtesy of CHRYSLER GROUP, LLC
  22. Lower the vehicle.
  23. Remove the Engine Lift Fixture (special tool #8984C, Fixture, Engine Lifting) (1).
  24. Position the engine harness on both right and left sides of the vehicle.
    GC0144407Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Ensure that the O-ring is fully seated into the cylinder block.

  25. Position the oil control valve (3) into the cylinder block.
  26. Securely tighten the oil control valve retaining bolt (2).
  27. Connect the oil control valve electrical connector (1).
  28. Install the intake manifold. Refer to INSTALLATION  .
    GC0144321Courtesy of CHRYSLER GROUP, LLC
  29. Install the generator. Refer to 5.7L .
  30. Install the cooling fan module (1). Refer to INSTALLATION .
    GC0146186Courtesy of CHRYSLER GROUP, LLC
  31. Position both heater hoses (2).
  32. Install both heater hose clamps (1).
    GC0145666Courtesy of CHRYSLER GROUP, LLC
  33. Position the upper radiator hose and secure the retainer (2) at the fan shroud.
  34. Connect the upper radiator hose to the thermostat housing and install the hose clamp (1).
  35. Raise and support the vehicle.
    GC0104231Courtesy of CHRYSLER GROUP, LLC
  36. Install the starter (1). Refer to INSTALLATION .
  37. Install the A/C compressor to the engine block. Refer to COMPRESSOR, A/C, INSTALLATION .
  38. Connect the transmission oil cooler lines to their retainer at the oil pan.
    GC0146154Courtesy of CHRYSLER GROUP, LLC
  39. Install both exhaust pipe/catalytic converters. Refer to CONVERTER, CATALYTIC, INSTALLATION .
  40. Position the left catalytic converter heat shield (2) install the retaining bolts (1) and securely tighten.
    GC0146185Courtesy of CHRYSLER GROUP, LLC
  41. Connect the lower radiator hose (3) to the radiator and install the hose clamp (2).
  42. Connect the lower radiator hose to the water pump and install hose clamp (1).
    GC0095646Courtesy of CHRYSLER GROUP, LLC
  43. If equipped, position the skid plate, install the four retaining bolts (2) and tighten to the proper specifications. Refer to TORQUE SPECIFICATIONS  .
  44. Lower the vehicle.
    GC0146182Courtesy of CHRYSLER GROUP, LLC
  45. Connect the left upstream 02 sensor electrical connector (1).
    GC0146183Courtesy of CHRYSLER GROUP, LLC
  46. Connect the right upstream 02 sensor electrical connector (1).
  47. Connect all remaining left and right engine harness electrical connectors.
    GC0146023Courtesy of CHRYSLER GROUP, LLC
  48. Install the cowl panel cover (2). Refer to COVER, COWL PANEL, INSTALLATION .
  49. Start the engine and inspect for leaks.
  50. Install the air cleaner and resonator assembly. Refer to INSTALLATION  .
    GC0145484Courtesy of CHRYSLER GROUP, LLC
  51. Fill the engine with oil. Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
  52. Fill the cooling system. Refer to COOLANT SYSTEM AIR EVACUATION .
  53. Connect the negative battery cable (2).
    GC0143807Courtesy of CHRYSLER GROUP, LLC
  54. Install the engine cover (2).
  55. Install the oil fill cap (1).
  56. 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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