Engine

Special Tool(s)

	2,200# Floor Crane, Fold Away 300-OTC1819E or equivalent
	Lifting Bracket, Engine 303-D089 (D93P-6001-A3) or equivalent
	Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

 WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

 WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

 WARNING: Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury.

All vehicles

1. Using the Floor Crane and the Engine Lifting Bracket, install the engine into the vehicle.

2. NOTICE: Do not tighten the engine insulator nut until the full weight of the engine is on the engine insulator or damage to the engine insulator may occur.

   Install the LH engine insulator nut.
   • Tighten to 63 Nm (46 lb-ft).

3. NOTICE: Do not tighten the engine insulator nut until the full weight of the engine is on the engine insulator or damage to the engine insulator may occur.

   Install the RH engine insulator nut.
   • Tighten to 63 Nm (46 lb-ft).

4. Install the clutch disc and pressure plate. Refer to Section 308-01 .

5. Install a new engine oil filter in the following sequence.
   1. Lubricate the oil filter gasket with clean engine oil and tighten until the seal makes contact.
   2. Using an oil filter strap wrench, tighten the filter an additional 270 degrees.

6. Install the A/C compressor and the 3 stud bolts.
   • Tighten to 25 Nm (18 lb-ft).

7. Position back the ground wire and install the nut to the RH engine insulator bracket.
   • Tighten to 25 Nm (18 lb-ft).

8. Connect the retainer at the back of the A/C compressor. Position back the engine wire harness retainers and install the nut.
   • Tighten to 10 Nm (89 lb-in).

9. Connect the Crankshaft Position (CKP) sensor electrical connector.

10. Connect the A/C compressor electrical connector.

11. Attach the 2 wire harness retainers to the oil pan.

12. Install the 2 wire harness retainer brackets on the oil pan studs and install the 2 nuts. Connect the wire retainer.
    • Tighten to 10 Nm (89 lb-in).

13. Connect the Engine Oil Pressure (EOP) switch electrical connector and the 2 wire retainers.

14. Connect the B+ wire to the generator and install the nut.
    • Tighten to 8 Nm (71 lb-in).

15. Connect the generator electrical connector.

16. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector.

17. Install the crossmember brace and the 6 crossmember brace bolts.
    • Tighten to 48 Nm (35 lb-ft).

18. Tighten the 2 crossmember brace nuts.
    • Tighten to 48 Nm (35 lb-ft).

19. Position the lower radiator hose assembly into the vehicle.
    • Connect the lower radiator hose to the radiator.

20. If equipped, connect the coolant hose to the oil cooler.

21. Position the Supercharger (SC) drive belt and install the tensioner and bolt.
    • Tighten to 48 Nm (35 lb-ft).

22. Rotate the SC drive belt tensioner clockwise and install the drive belt onto the SC drive pulley.

23. Rotate the accessory drive belt tensioner clockwise and install the accessory drive belt.

24. Connect the PCM electrical connector.

25. Connect the 16-pin electrical connector and attach the 2 wiring retainers.

26. Connect the 2 heater hoses to the coolant tube assembly at the rear of the engine.

27. Connect the coolant hose to the coolant pump.

28. Connect the coolant hose to the coolant tube assembly (above the generator).

29. Connect the coolant hose to the thermostat housing.

30. Connect the coolant hose to the Charge Air Cooler (CAC).

31. NOTE: RH bolt shown, LH similar.

    Install the cooling fan assembly and the 2 bolts.
    • Tighten to 8 Nm (71 lb-in).

32. Connect the cooling fan electrical connector.

33. Connect the upper radiator hose to the thermostat housing.

34. Connect the fuel supply tube. Refer to Section 310-00 .

35. Connect the Evaporative Emission (EVAP) tube quick connect coupling and the brake booster vacuum supply tube to the Throttle Body (TB) spacer. Refer to Section 310-00 .

36. Lift the cowl screen and install the ground strap bolt.
    • Tighten to 10 Nm (89 lb-in).
    • Attach the wiring retainer to the cowl.

37. Install the 2 cowl vent screen plastic rivets.

Vehicle equipped with the cooling package

38. Position the transmission cooler hoses and install the bolt.
    • Tighten to 8 Nm (71 lb-in).

39. Connect the 2 oil hoses to the oil filter adapter and install the 2 retaining clips.

All vehicles

40. Install the SC coolant pump, bolt and the 2 nuts.
    • Tighten the bolt to 10 Nm (89 lb-in).
    • Tighten the nuts to 11 Nm (97 lb-in).

41. Connect the SC coolant pump electrical connector and retainer.

42. Connect the lower coolant hose to the SC coolant pump.

43. Connect the upper coolant hose to the SC coolant pump.

44. Install the SC coolant degas bottle. Refer to Section 303-03B .

45. Install the engine coolant degas bottle. Refer to Section 303-03A .

46. Install the brake booster. Refer to Section 206-07 .

47. Install the battery tray and battery. Refer to Section 414-01 .

48. Install the Air Cleaner (ACL) assembly and ACL outlet pipe. Refer to Section 303-12 .

49. NOTE: Use the hood hinge location index marks made during removal to aid in hood installation.

    Install the hood and the 4 bolts.
    • Tighten to 12 Nm (106 lb-in).

50. Attach the 2 windshield washer hose retainers and connect the 2 windshield washer hose C-Lock Couplers. Refer to Section 501-16 .

51. Install the 2 windshield washer hose retainers and the 8 hood insulation pin-type retainers (2 shown).

52. Fill the engine with clean engine oil.

53. Fill and bleed the engine cooling system. Refer to Section 303-03A .

54. Fill and bleed the SC cooling system. Refer to Section 303-03B .

55. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.