Engine, Installing

Special tools and workshop equipment required

Scissor Lift Table VAS 6131
Powertrain Support Posts J-48839
Driver Side Engine Lifting Bracket 10242-1
Passenger Side Engine Lifting Bracket 10242-2

Fig 1: Identifying Air Inlet Hose And Upper Intake Manifold

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NOTE: If installing a replacement engine, transfer components such as engine mount brackets, block heater, accessories, heater hoses and tubes to the replacement engine.

-- If required, remove the upper intake manifold. Refer to UPPER INTAKE MANIFOLD .

Fig 2: Identifying Driver Side Engine Lifting Bracket 10242-1 And Bolts

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-- Install the driver side engine lifting bracket 10242-1 (1) on the LH cylinder head with bolts (2) provided with the Engine Lifting Bracket. Tighten the bolts to 21 Nm (15 ft. lbs.).

Fig 3: Identifying Passenger Side Engine Lifting Bracket 10242-2 And Bolts

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-- Install the passenger side engine lifting bracket 10242-2 (1) on the RH cylinder head with bolts (2) from the Engine Lifting Bracket. Tighten the bolts to 21 Nm (15 ft. lbs.).

Fig 4: Identifying Load-Leveling Lifting Sling, Engine Lifting Brackets And Engine Hoist

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-- Position a load-leveling lifting sling (2), such as OTC® 4305 Engine Load Leveler or equivalent, between the engine lifting brackets (3) and an engine hoist (1).

Fig 5: Identifying Transmission Upper Bellhousing-To-Block Bolts, Transmission And Engine

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-- Install the transmission (2) to the engine (1) if required. Secure with six transmission upper bellhousing-to-block bolts (3) tightened to 70 Nm (52 ft. lbs.).

Fig 6: Identifying Safety Straps

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-- Position the engine/transmission assembly on the scissor lift table VAS 6131 and powertrain support posts J-48839.

-- Loosen the cradle engine mounts to allow movement for positioning onto the engine locating holes on the engine block and oil pan rail. Tighten the post mounts to the cradle frame. Secure the engine/transmission assembly to the dolly/cradle with safety straps (4). Remove the engine lifting brackets.

-- If required, install the following components for installation on the replacement engine:

Accessory drive belt tensioner
Upper intake manifold support bracket
Block heater (if equipped)

Fig 7: Identifying RH Engine Mount Bracket Bolts

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-- Position the engine/transmission assembly under the vehicle. Slowly lower the vehicle in short length spans. Inspect at each interval for potential engine or transmission contact to vehicle components. Move the cradle/dolly fixture as necessary to allow for clearance.

-- Install three bolts (1) to the RH engine mount bracket (2) and tighten bolts (1) to 55 Nm (41 ft. lbs.).

Fig 8: Identifying LH Engine (Transmission) Mount Bracket Bolts

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-- Install two bolts (1) to the LH engine (transmission) mount bracket (2).

-- Position the main wire harness onto the engine.

Fig 9: Identifying Gearshift Cable, Bracket, Output Shaft Speed Sensors Connectors, Wire Harness Retainer And Gearshift Cable Bracket

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-- Engage the wire harness retainer (1) to the gearshift cable bracket (4).

-- Connect two output shaft speed sensors connectors (2 and 3).

-- Connect the gearshift cable (5) from the bracket (4).

Fig 10: Identifying Gearshift Cable And Transmission Manual Valve Lever

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-- Connect the gearshift cable (1) from transmission manual valve lever (2).

Fig 11: Identifying Transmission Input Shaft Speed Sensor Connector And Oil Cooler Lines

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-- Connect the oil cooler lines (2) to transmission.

-- Connect the transmission input shaft speed sensor connector (1).

Fig 12: Identifying Transmission Solenoid Harness Connector And Main Wire Harness Retainer

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-- Engage the main wire harness retainer (1) to the valve body pan.

-- Connect transmission solenoid harness connector (2).

Fig 13: Identifying Torque Converter-To-Flexplate Bolt And Transmission-To-Engine Lower Bolts

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-- Raise and support the vehicle.

-- If required, install the four transmission-to-engine lower bolts (2) and tighten to 70 Nm 52 ft. lbs.).

-- If required, install the torque converter-to-flexplate bolts (1) and tighten to 88 Nm (65 ft. lbs.).

Fig 14: Identifying Transmission Torque Converter Housing Dust Cover And Rubber Plugs

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-- If required, install the transmission torque converter housing dust cover (1) and rubber plugs (2).

Fig 15: Identifying Rear Engine Mount Isolator Bolt

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-- Install the rear engine mount bracket (1) with four bolts (2). Tighten bolts (2) to 110 Nm (81 ft. lbs.)

-- Install the bolt (3) to the rear engine mount isolator and tighten to 66 Nm (44 ft. lbs.).

Fig 16: Identifying Heater Core Supply Tube And Bolts

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-- Lower the vehicle.

-- If required, install the heater core supply tube (1) with two bolts (2) and tighten to 12 Nm (106 in. lbs.).

Fig 17: Identifying Upper Intake Manifold Support Brackets And Bolts

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-- Install the LH upper intake manifold support brackets (1). Loosely install the studbolts (2).

Fig 18: Identifying Main Wire Harness Retainers

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-- Engage three main wire harness retainers (1) to the right cylinder head cover.

Fig 19: Identifying Oil Pump Solenoid Electrical Connector And Wire Harness Retainer

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-- Raise and support the vehicle.

-- Connect the oil pump solenoid electrical connector (2).

-- Engage the wire harness retainer (1) to the engine block.

Fig 20: Identifying Wire Harness Retainer

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-- Install the power steering pump and bracket as an assembly with three bolts (1) and tighten to 25 Nm (18 ft. lbs.).

-- Engage the wire harness retainer (2) to the power steering pump.

Fig 21: Identifying Power Steering Pump Heat Shield With Bolts

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-- Install the power steering pump heat shield (1) Tighten bolts (2) to 25 Nm (18 ft. lbs.).

Fig 22: Identifying Crankshaft Position (CKP) Sensor Electrical Connector, Wire Harness Retainers And Downstream Oxygen Sensor Connector

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-- Connect the power cord to the engine block heater (if equipped).

-- Engage the downstream oxygen sensor connector (4) to the engine mount.

-- Engage one wire harness retainer (2) to the engine block and one wire harness retainer (1) to the transmission mounting stud.

-- Connect the Crankshaft Position (CKP) sensor electrical connector (3).

Fig 23: Identifying Heat-Shield

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-- Position the heat-shield (1) over the Crankshaft Position (CKP) sensor.

Fig 24: Identifying Rear Engine Mount Heat Shield With Bolts

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-- Install the rear engine mount heat shield (2). Tighten bolts (1) to 14 Nm (124 in. lbs.).

Fig 25: Identifying A/C Compressor

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-- Install the A/C compressor (1). Refer to Removal and Installation .

Fig 26: Identifying Lower Radiator Hose

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-- Install the lower radiator hose (1).

Fig 27: Field Generator Connector, B+ Retainer And B+ Cable

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-- Install the starter. Refer to STARTER (CJRA) .

Fig 28: Identifying Front Engine Mount Bracket With Bolts

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-- Install the front engine mount bracket (1). Tighten bolts (2) to 55 Nm (41 ft. lbs.).

Fig 29: Identifying Crossunder Pipe

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-- Install both catalytic converters (3) and connect the oxygen sensor connectors to the main wire harness. Refer to CATALYTIC CONVERTER

-- Install the crossunder pipe (2). Refer to EXHAUST CROSSUNDER PIPE

-- Install the front fore and aft crossmember (1).

Fig 30: Identifying Drive Axles

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-- Install the intermediate shaft and both drive axles (2). Refer to Removal and Installation .

Fig 31: Identifying Right Lower Splash Shield

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-- Install the right splash shield (2).

Fig 32: Identifying Left Lower Splash Shield

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-- Install left lower splash shield (2).

Fig 33: Exploded View Of Wheel Assembly

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-- Install both front tire and wheel assemblies (1). Refer to Removal and Installation .

Fig 34: Identifying Belly Pan And Bolts, Removal & Installation

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-- Install the belly pan.

-- Lower the vehicle.

Fig 35: Identifying Electrical Connector And Wire Harness Retainers

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-- Engage the wire harness retainer (2) to the upper intake manifold support bracket mounting stud.

-- Engage the wire harness retainer (3) to the intake manifold support bracket.

-- Connect the electrical connector (1) to the right Camshaft Position (CMP) sensor.

Fig 36: Identifying Positive Crankcase Ventilation (PCV), Vapor Purge And Brake Booster

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-- Connect the following hoses to the upper intake manifold:

Positive Crankcase Ventilation (PCV) (3)
Vapor purge (6)
Brake booster (2).

-- Engage the ETC harness to the clip (8) on the throttle body. Engage the wire harness retainers (4 and 5) to the upper intake manifold near the MAP sensor and reposition the wire harness.

-- Connect the electrical connectors to the Manifold Absolute Pressure (MAP) sensor (1) and the Electronic Throttle Control (ETC) (7).

Fig 37: Identifying Electrical Connectors And Wire Harness Retainers

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-- Engage two wire harness retainers (1) to the right cylinder head cover.

-- Connect the electrical connectors (2) to the variable valve timing solenoids on the right cylinder head.

Fig 38: Identifying Engine Injection/Ignition Harness And Engine Oil Pressure/Temperature Harness

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-- Connect the main harness to the engine oil pressure/temperature harness (2) at the rear of the left cylinder head.

-- Connect the main harness to the engine injection/ignition harness (1) at the rear of the left cylinder head.

Fig 39: Identifying Engine Coolant Temperature (ECT) Sensor Connector And Left Camshaft Position (CMP) Sensor

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-- Engage the main wire harness retainer (1) to the rear of the lower intake manifold.

-- Engage one main wire harness retainer (2) to the cylinder head cover and one main wire harness retainer (4) to the cylinder head cover mounting stud.

-- Connect the left Camshaft Position (CMP) sensor (5).

-- Connect the Engine Coolant Temperature (ECT) sensor connector (3).

Fig 40: Identifying Upper Wire Harness Retainers

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-- Engage two lower wire harness retainers (3) to the intake manifold support brackets.

-- Engage two upper wire harness retainers (2) to the intake manifold support brackets.

Fig 41: Identifying Variable Valve Timing Solenoid Connectors

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-- Engage three wire harness retainers (1) to the left cylinder head cover.

-- Connect the electrical connectors (2) to the variable valve timing solenoids on the left cylinder head cover.

Fig 42: Identifying Electrical Connectors And Fuel Purge Solenoid Wire Harness Retainer

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-- Connect the electrical connector (2) to the A/C pressure transducer.

-- Engage the fuel purge solenoid wire harness retainer (1) to the engine cowl.

-- Connect the electrical connector (3) to the fuel purge solenoid.

Fig 43: Generator Field Electrical Connector & Generator Retainers

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-- Install the generator (2). Refer to GENERATOR (CJRA) .

Fig 44: Serpentine Belt With Routing

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-- Install the accessory drive belt (7). Refer to ACCESSORY DRIVE BELT .

Fig 45: Identifying Heater Core Return Hose

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-- Connect the heater core return hose (1).

Fig 46: Identifying Heater Core Supply Hose

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-- Connect the heater core supply hose (1).

Fig 47: Cooling Fan & Serpentine Belt

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-- Install the cooling fan module (1). Refer to COOLING FAN .

Fig 48: Identifying Air Inlet Hose And Upper Intake Manifold

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-- Install the upper intake manifold (2). Refer to UPPER INTAKE MANIFOLD .

Fig 49: Identifying Heater Core Return Tube With Nut And Bolt

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-- Install the heater core return tube (1) with the nut (2) and bolt (3).

Fig 50: Identifying Hose Retainer And Upper Radiator Hose

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-- Install the upper radiator hose (2) and engage the hose retainer (1) to the intake manifold.

Fig 51: Identifying Coolant Recovery Bottle

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-- Install the coolant recovery bottle (1). Refer to COOLANT RECOVERY RESERVOIR .

Fig 52: Identifying Fuel Line

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-- Disconnect the fuel line (1) from the fuel rail inlet.

Fig 53: Identifying Resonator

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-- Install the resonator (1). Refer to AIR CLEANER RESONATOR .

Fig 54: Air Cleaner Body

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-- Install the air cleaner housing (1). Refer to AIR CLEANER HOUSING .

Fig 55: Identifying Mounting Bracket

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-- Install the electric vacuum pump and mounting bracket (1). Refer to Removal and Installation .

Fig 56: Identifying Engine Cover

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-- Fill engine crankcase with proper oil to correct level.

-- Evacuate and recharge air conditioning system. Refer to Description and Operation .

-- Fill cooling system. Refer to COOLING SYSTEM DRAINING AND FILLING .

-- Install the engine cover (1).

-- Connect the negative battery cable. Refer to BATTERY, DISCONNECTING AND CONNECTING .

-- Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level.

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.