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Engine Installation

WARNING: This page is about a different car, the 2009 Jeep Grand Cherokee. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: ENGINE LIFTING POINTS
GC0095629Courtesy of CHRYSLER LLC
1 - REAR ENGINE LIFT WITH CLEVIS CONNECTOR
2 - FRONT ENGINE LIFT WITH CLEVIS CONNECTOR
  1. Carefully align the engine assembly in the engine bay area and align with the transmission, Do Not  lower the engine.
    Fig 2: TORQUE CONVERTER TO FLEX PLATE BOLTS
    GC0081174Courtesy of CHRYSLER LLC
    1 - TORQUE CONVERTER BOLTS
    2 - TRANSMISSION COOLER LINES
  2. Align the engine to transmission, and lower the engine mounts into position.
  3. Remove engine lifting device.
  4. Route the transmission wiring harness through to the rear of the engine.
  5. Raise and support the vehicle.
  6. Install accessible engine to transmission housing bolts. Tighten bolts to 68 N.m (50 ft. lbs.).
  7. Support the transmission and remove the rear transmission crossmember retaining bolts.
  8. Lower the transmission and install the upper transmission to engine fasteners. Tighten bolts to 68 N.m (50 ft. lbs.).
  9. Raise the transmission and install the transmission crossmember.
  10. Install the flex plate to torque converter bolts (1).
  11. Tighten engine mount through bolts to 30 N.m (22 ft. lbs.).
    Fig 3: STARTER AND MAIN ENGINE HARNESS GROUND
    GC0118637Courtesy of CHRYSLER LLC
    1 - ENGINE WIRING HARNESS GROUND
    2 - STARTER
    3 - LEFT ENGINE MOUNT
  12. Install the engine ground wire above the starter (1). Tighten bolt to 14 N.m (10 ft. lbs.).
  13. Install the starter wiring.
    Fig 4: CRANKSHAFT POSITION SENSOR
    GC0080495Courtesy of CHRYSLER LLC
    1 - HEAT SHIELD
    2 - CRANKSHAFT POSITION SENSOR
  14. Connect the crankshaft sensor (2) wiring harness connector.
  15. Route the transmission wiring harness and make necessary sensor connections at the transmission.
  16. Install the front axle housing. Refer to Differential and Driveline/Front Axle - C200FE - Installation .
    Fig 5: FRONT EXHAUST PIPE AT MUFFLER
    GC0118633Courtesy of CHRYSLER LLC
    1 - CROSS OVER
    2 - FRONT EXHAUST PIPE
    3 - MUFFLER
  17. Install the catalytic converter and front exhaust pipe (2).
  18. Install the transfer case shield.
  19. Lower the vehicle.
    Fig 6: FUEL LINES
    GC0118636Courtesy of CHRYSLER LLC
    1 - FUEL SUPPLY AND RETURN LINES FROM FUEL TANK
    2 - MAIN ENGINE WIRING HARNESS
  20. Install the fuel supply and return lines to the fuel pipe.
    Fig 7: HEATER HOSES
    GC0118635Courtesy of CHRYSLER LLC
    1 - LOW PRESSURE A/C HOSE
    2 - HOSE AND JUNCTION
  21. Attach the axle vent tube to the wiring harness.
  22. Secure the transmission oil level indicator.
  23. Install the engine cover bracket.
  24. Connect the A/C lines (1) at the expansion valve.
  25. Connect the coolant hose, at the outer housing, by the generator.
  26. Connect the coolant bypass hose at the cooler tube (2) on the right cylinder head.
  27. Connect the heater hose, at the cooler tube (2) on the right cylinder head.
    Fig 8: POWER DISTRIBUTION CENTER AND FRONT CONTROL MODULE
    GC0118631Courtesy of CHRYSLER LLC
    1 - POWER DISTRIBUTION CENTER (PDC)
    2 - RELAY CENTER
    3 - FRONT CONTROL MODULE (ECM)
    4 - BATTERY
  28. Connect the wiring harness connectors to the PDC (1).
  29. Connect the generator wiring.
  30. Connect the A/C compressor wiring harness connector.
  31. Connect the PCM wiring harness connectors.
  32. Install the PDC (1) bracket and mount the PDC (1).
    NOTE: Do Not connect the negative battery cable when installing the battery.
  33. Install the battery (4) and tray.
    Fig 9: COOLANT MODULE
    GC0118634Courtesy of CHRYSLER LLC
    1 - RADIATOR
    2 - A/C CONDENSER
    3 - TRANSMISSION COOLER
    4 - POWER STEERING COOLER
    5 - CHARGE AIR COOLER
  34. Install the coolant module assembly.
  35. Connect the transmission cooler (3) and power steering cooler (4) lines to the coolant module.
  36. Connect the suction/discharge lines at the A/C condenser and accumulator.
  37. Connect the power steering reservoir hose to pump, at the reservoir.
  38. Install the charge air inlet and outlet hoses at cooler (5).
  39. Install the front core support bracket.
  40. Install the front grille and upper radiator core support bracket with the hood latch.
  41. Raise and support the vehicle.
    Fig 10: CATALYTIC CONVERTER AT TURBOCHARGER
    GC0118632Courtesy of CHRYSLER LLC
    1 - CLAMP
    2 - CATALYTIC CONVERTER
  42. Install the power steering hydraulic lines at cooling fan. Refer to Steering/Pump/HOSE, Power Steering - Installation .
  43. Install the lower radiator hose.
  44. Lower the vehicle.
  45. Install lower catalytic converter exhaust clamp (1) behind right cylinder head.
    Fig 11: Strut Tower Support
    GC0081931Courtesy of CHRYSLER LLC
    1 - AIR CLEANER OUTLET TUBE
    2 - STRUT TOWER SUPPORT
    3 - TURBOCHARGER
    4 - CHARGE AIR INLET TUBE
  46. Install the turbocharger (3) upper heat shield.
  47. Install air cleaner housing and connect the air cleaner outlet tube (1) to the turbocharger. See Engine/Air Intake System/BODY, Air Cleaner - Installation .
  48. Install the strut tower support (2).
  49. Fill all appropriate fluid levels.
  50. Evacuate and recharge air conditioning. Refer to Heating and Air Conditioning/Plumbing - Standard Procedure .
  51. Connect the negative battery cable.
    WARNING: High-pressure fuel lines deliver fuel under extreme pressure from the injection pump to the injectors. This maybe as high as 1600 bar (23,200 psi). Use extreme caution when inspecting for high-pressure fuel leaks. Inspect high-pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system. Fuel under this amount of pressure can penetrate skin causing serious or fatal injury. 
  52. Start engine, allow to warm, turn engine off and inspect for leaks.
  53. Bleed power steering system using the scan tool procedure. Refer to Steering - Standard Procedure .
  54. Install lower splash shields. Refer to Body/Exterior/SHIELD, Splash - Installation .
  55. Install front tires. Refer to Tires and Wheels - Specifications .
    Fig 12: ENGINE COVER
    GC0118402Courtesy of CHRYSLER LLC
    1 - OIL FILLER CAP
    2 - COVER FASTENERS
    3 - ENGINE COVER
  56. Install engine cover (3). See Engine - Installation .
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