C. LX (AWD and RWD) Engine Replacement
1. Install the # 2 connecting rod cap and finger start the connecting rod bolts.2. Install the engine oil pan with four bolts and snug tight.
3. Lower the vehicle.
4. Remove the cowl grill push pins.
5. Remove the cowl grill (Figure 32).
6. Remove the strut tower structural bar attached to the right and left strut tower (Figure 32).
7. Remove the engine air inlet filter box.
8. Remove the tube connecting the air filter box to the throttle body.
9. Remove the Positive Crankcase Ventilation hose.
10. Remove the EGR tube.
11. Remove the brake booster and other vacuum lines from the intake manifold.
12. Disconnect the electrical harness from throttle body.
13. Disconnect the electrical lead to the MAP sensor.
14. Remove the upper intake plenum from the engine, its brackets and pencil braces.
15. Remove the engine foam silencer pad from the top of the engine.
16. Disconnect the electrical connections to the generator.
17. Remove the generator.
18. Place disposable towels underneath the fuel line disconnect at the engine.
19. Disconnect the fuel line at the engine disconnect.
20. Cap the fuel supply line opening.
21. Cap the engine fuel line opening.
22. Remove the radiator cap, drain the engine coolant and save for reuse.
23. Discharge the air conditioning system using an appropriate refrigerant recovery system.
24. Disconnect the left oxygen sensor from the engine wiring harness.
25. Disconnect the left side ground strap assembly on the left engine valve cover and at the cylinder head.
26. Disconnect the right side oxygen sensor from the engine electrical harness.
27. Disconnect the engine harness from the IP chassis harness.
28. Remove the upper radiator hose completely.
29. Remove the serpentine belt.
30. Remove the power steering pump and set it aside.
31. Remove the lower coolant hose from the engine.
32. Disconnect the high pressure line to the air conditioning compressor.
33. Using clean caps, plug the end of the high pressure air conditioning line and the open port in the air conditioning compressor.
34. Disconnect the low pressure line to the air condition compressor.
35. Using clean caps, plug the end of the low pressure air conditioning line and the open port in the air conditioning compressor.
36. Remove the coolant recovery bottle hose.
37. Disconnect heater hose from the rear of the engine. the engine.
38. Remove the engine wire harness / support bracket from the top of the transmission bell housing.
39. Remove the ground strap from the right side transmission bell housing bolt (Figure 33).
40. Remove the remaining upper four transmission bell housing bolts.
41. Raise the vehicle.
42. Remove the crank position sensor.
43. Disconnect the electrical connections at the starter.
44. Remove the starter, spacer, wire harness hanger and the dust shield.
45. Remove the six bolts fastening the torque converter to the drive plate.
46. Remove the right side dust shield where the transmission bell housing and engine join.
47. Remove the air conditioning compressor and set aside away from the engine.
48. Remove the remaining transmission bell housing to engine bolts.
49. Remove the heat shield and the left exhaust pipe flange from the engine exhaust manifold.
50. Remove the right side exhaust pipe from the engine exhaust manifold.
51. Remove the coolant hose from the heater to the oil cooler and set aside.
52. Remove the right and left engine mount bolts from the bottom of the suspension cradle.
53. Lower the vehicle.
54. If so equipped, disconnect and relocate the 110 v power cord of the block heater onto the engine (Figure 33).
55. Prop the hood fully open NOT using the vehicle hood prop rod.
56. Support the transmission using a suitable floor jack.
57. Connect one end of the engine lifting bracket from special tool kit 8534 to the right rear of the cylinder head outer most bolt access hole with a bolt and tighten (Figure 34).
58. Install a bolt into the inner most bolt access hole next to the engine lift bracket to position the engine lift bracket (Figure 34).
59. Attach the engine hoisting chain to the left timing cover engine lift eye and to the engine lift bracket installed in Step 57 at the rear of the right cylinder head (Figure 35).
60. Carefully remove the engine from the vehicle.
61. For All Wheel Drive models: Remove the oil pan.
62. Set the old engine in a suitable cradle to prevent the engine from tipping.
63. Disconnect connectors for fuel injectors, ignition coil packs, temperature sensors, knock sensor, EGR valve, cam position sensor, and oil pressure sensor.
64. Remove engine wiring harness.
65. Remove the left exhaust manifold heat shield.
66. Remove the left exhaust manifold.
67. Remove the left engine mount and bracket.
68. Remove the right exhaust manifold heat shield.
69. Remove the right exhaust manifold.
70. Remove the right engine mount and bracket.
71. Remove the drive plate, and drive plate backing plate. Discard the old bolts.
72. Remove the EGR valve.
73. Remove the accessory drive idler pulley.
74. Remove the accessory drive belt tensioner.
75. Remove the coolant hoses from the engine thermostat housing.
76. Remove the engine block heater (if so equipped).
77. Remove the coil packs.
78. Remove the ignition noise suppression capacitor from the left engine cylinder head cover.
79. Remove the oil fill cap.
80. Remove the oil fill tube.
81. Remove the PCV valve.
82. Remove the crankshaft damper.
83. Remove the block heater if so equipped.
84. Remove engine lifting chains and brackets.
85. Install the block heater onto the new engine and tighten the bolt to 17 in. lbs. (2 N.m) if so equipped.
86. Install crankshaft damper and tighten the damper bolt to 70 ft. lbs. (95 N.m).
87. Install the PCV valve onto the new engine.
88. Install the oil fill tube onto the new engine and tighten.
89. Install ignition noise suppression capacitor to the left engine cylinder head cover and tighten fastener.
90. Install the coil packs and tighten the fasteners to 60 in. lbs. (6.7 N.m).
91. Install coolant hose to the thermostat housing.
92. Install the block heater (if so equipped) and lay the 110 v power cord on top of the engine.
93. Install accessory drive belt tensioner and tighten the bolt to 40 ft. lbs. (54 N.m).
94. Install accessory drive idler pulley and tighten the bolt to 250 in. lbs. (28 N.m).
95. Remove the plug in the EGR passage at the rear of the right cylinder head.
96. Install the EGR valve to the cylinder head using a new gasket. Tighten the fasteners to 97 in. lbs. (11 N.m).
97. Remove the old thread locking compound from the threaded holes at the end of the crankshaft where the drive plate mounts.
98. Install the drive plate and drive plate backing plates using new bolts. Tighten the bolts to 55 ft. lbs. (75 N.m).
99. Apply a thin coat of universal suspension grease into the end of the crankshaft pilot hole for the torque converter.
100. Install the right engine mount and bracket. Tighten the bolts to 55 ft. lbs. (75 N.m).
101. Install the right exhaust manifold using a new gasket. Tighten the bolts to 200 in. lbs. (23 N.m).
CAUTION:
Do not over tighten.
102. Install the right exhaust manifold heat shield and tighten the bolts to 105 in. lbs. (12 N.m).
103. Install the left engine mount and bracket. Tighten the bolts to 55 ft. lbs. (75 N.m).
104. Install the left exhaust manifold using a new gasket. Tighten the bolts to 200 in. lbs. (23 N.m).
CAUTION:
Do not over tighten.
105. Install the left exhaust manifold heat shield and tighten the fasteners.
106. Install the engine wire harness.
107. Connect to the engine wire harness the fuel injectors, ignition coil packs, temperature sensors, knock sensor, EGR valve, cam position sensor, and oil pressure sensor.
108. Connect one end of the engine lifting bracket from special tool kit 8534 to the right rear of the cylinder head outer most bolt access hole with a bolt and tighten (Figure 34).
109. Install a bolt into the inner most bolt access hole next to the engine lift bracket to position the engine lift bracket (Figure 34).
110. Attach the engine hoisting chain to the left timing cover engine lift eye and to the engine lift bracket installed in Step 108 at the rear of the right cylinder head (Figure 35).
111. For All Wheel Drive vehicles, complete the following steps.
a. Clean all surfaces of the oil pan from the old engine.
b. Remove the oil cooler and oil filter and set aside.
c. Using a putty knife, separate the oil pan from the oil pan gasket of the new engine. Carefully remove the oil pan. The oil pan gasket should remain attached to the block.
NOTE:
f the oil pan gasket is attached to the block at all four corners, be careful not to dislodge the gasket while completing this section.
d. If the oil pan gasket is still attached to the engine at all four corners, use a clean shop cloth and wipe the oil pan gasket surfaces and continue with Step 111(i). If the engine oil pan gasket was removed or has come loose, continue with Step 111(e).
CAUTION:
Do not use any cleaning fluids (such as brake cleaner) to clean gasket surfaces. Damage to the gasket will result.
e. Clean the block oil pan gasket surface.
f. Obtain new oil pan gasket P/N 04792869AA.
g. Apply a 1/8 inch bead of Mopar Engine RTV (PN 82300234) at the parting line of the oil pump housing and the rear seal retainer (Figure 36).
h. Align the oil pan gasket onto the engine oil pan.
i. Raise the oil pan to the engine and hand tighten all the bolts and nuts.
j. Align the rear face of the engine oil pan with the rear face of the engine. The plane of the back of the engine oil pan must be on the same plane as the back of the engine. Use a suitable straight edge to check if the rear oil pan face and the rear block face of the block are properly aligned.
k. Starting at the center of the oil pan and working towards the ends, tighten the 8 mm oil pan bolts and nuts to 20 ft. lbs. (28 N.m).
l. Check the alignment of the rear face of the oil pan with the rear face of the engine with a straight edge. If they are out of alignment, repeat Steps 111(j) and 111(k).
CAUTION:
Steps 111(j) through 111 (l) must be followed to avoid damage to the oil pan.
m. Tighten the two 6 mm engine oil pan bolt located at the rear of the oil pan to 105 in. lbs (12 N.m).
n. Wipe clean both the upper engine oil cooler sealing "O" ring and the oil filter mounting surface.
o. Position oil cooler to fitting on oil pan. The notch in the engine oil pan oil cooler pad must fit into the cut-out of the oil cooler.
p. While holding the engine oil cooler in position, install the oil cooler/filter nipple and tighten to 45 ft. lbs. (61 N.m).
NOTE:
Do not over tighten. Damage to the oil cooler will occur.
112. Install a new oil filter and tighten to 106 in. lbs. (12 N.m).
113. Carefully install the engine into the vehicle. Make sure the engine to transmission dowels align with the transmission bell housing.
114. Install the two upper engine-to-transmission bell housing bolts and snug the bolts.
115. Remove the floor jack supporting the transmission.
116. Remove the engine lifting chains and bracket.
117. Remove the prop holding the hood fully open and use the vehicle hood prop.
118. Install the connector 110 v power cord to the to the block heater.
119. Raise the vehicle.
120. Install the right and left engine mount nuts on the studs securing the engine mounts to the suspension cradle. Tighten the nuts to 55 ft. lbs. (75 N.m).
121. Install two lower 10 mm engine oil pan to transmission bell housing bolts nearest to the drive plate bolt access and tighten to 55 ft. lbs. (75 N.m) (Figure 16).
122. Install the hose to the oil cooler from the heater.
123. Install the right side exhaust pipe to the engine exhaust manifold and tighten the bolts to 25 ft. lbs. (34 N.m).
124. Install the left side exhaust pipe and heat shield to the engine exhaust manifold and tighten the bolts to 25 ft. lbs. (34 N.m).
125. Install the right dust shield and tighten bolts to 95 in. lbs. (10 N.m).
126. Install the remaining 10 mm engine to transmission bell housing bolts (except the right and left bolts flanking the two center bolts installed in Step 114) and tighten to 40 ft. lbs. (55 N.m).
127. Install the air conditioning compressor. Fasten the bracket holding the transmission oil cooler lines onto compressor with the rear most bolt. Tighten the bolts to 19 ft. lbs. (26 N.m).
128. Align the torque converter to the drive plate and install the bolts. Tighten the bolts to 55 ft. lbs. (75 N.m).
129. Install the starter, spacer, wire harness hanger and dust shield. Tighten the bolts to 40 ft. lbs. (54 N.m) (Figure 37).
130. Connect the electrical harness connections to the starter.
131. Install the crank position sensor and connect it to the wiring harness.
132. Install the torque converter access cover (Figure 16) and tighten the fastener to 97 in. lbs. (11 N.m).
133. For AWD model vehicles:
a. Lower the vehicle to a suitable height to perform suspension operations.
b. Install front differential and tighten bolts to 47 ft. lbs. (64 N.m).
c. Remove the opening plugs from the differential.
d. Align the propeller shaft to the differential flange to the mark made in Step 13(s) of Section A. Install the four bolts and tighten to 47 ft. lbs. (64 N.m).
e. Install the right strut to the lower control arm. Tighten the pinch bolts to 84 ft. lbs. (114 N.m).
f. Install the right tie rod end to the steering knuckle and tighten the nut to 60 ft. lbs. (81 N.m).
g. Install the right axle shaft into the differential housing.
h. Install the right axle shaft into the steering knuckle.
i. Install the left differential extension housing and tighten bolts to 48 ft. lbs. (65 N.m).
j. Install the left strut to lower control arm and tighten the pinch bolts to 84 ft. lbs. (114 N.m).lbs.
k. Install the left tie-rod end to the steering knuckle and tighten the nut to 60 ft. lbs. (81 N.m).
l. Install left axle shaft into the differential extension housing.
m. Install left axle shaft into the steering knuckle.
n. Install left and right sway bar link bolts to the strut clevis brackets and tighten bolts to 95 ft. lbs. (128 N.m).
o. Install right and left hub nuts to right and left axles and tighten to 157 ft. lbs. (213 N.m).
p. Install right and left brake pads and calipers. Tighten caliper bolts to 44 ft. lbs. (60 N.m).
q. Install right and left upper control arm ball joint to steering knuckle.
Tighten the bolt to 35 ft. lbs. (47 N.m) + 90.
r. Install right and left vehicle speed sensors to the steering knuckle.
Tighten bolts to 96 in. lbs. (11 N.m).
s. Install right and left front wheel and tire assembly and tighten the lug nuts to 110 ft. lbs. (149 N.m).
t. Check the front differential for proper differential oil level. Adjust as needed. Continue with Step 133.
134. For RWD models:
a. Install the steering rack to the sub-frame and tighten the bolts to 75 ft.lbs. (102 N.m).
b. Align the steering coupler to the steering gear using the mark made in Step 16(a) of Section A.
c. Install the steering coupler bolt and tighten to 40 ft. lbs. 54 N.m).
135. Install the lower plastic splash shield under the engine.
136. Lower the vehicle.
137. Install the left engine-to-transmission bell housing bolt next to the two center engine to transmission bell housing bolts. Tighten the left and the two center bolts to 55 ft. lbs. (75 N.m).
138. Install the engine-to-chassis ground to the remaining right engine-to-transmission bolt. Tighten the bolt to 55 ft. lbs. (75 N.m).
139. Attach the engine wire harness/support bracket to the top of the transmission bell housing.
140. Connect the heater hose at the rear of the engine.
141. Connect the coolant recovery bottle hose.
142. Remove the caps from the air conditioning lines and compressor.
143. Connect both the high and low pressure lines to the air conditioning compressor.
144. Install the lower radiator hose.
145. Install the power steering pump and tighten the bolts to 21 ft. lbs. (28 N.m).
146. Install the serpentine belt.
147. Install the upper radiator hose.
148. Connect the engine harness to the chassis harness.
149. Connect the right side oxygen sensor.
150. Connect the left side ground strap to the left valve cover and to the cylinder head.
151. Connect the right oxygen sensor.
152. Connect chassis fuel line to the engine fuel rail.
153. Install generator and support bracket. Tighten the bottom bolts to 48 ft. lbs. (65 N.m). Leave the upper bolt with the support bracket loose at this time.
154. Connect the electrical harness to the generator.
155. Install engine silencer pad onto the engine.
156. Install the upper intake plenum onto the engine, its brackets and pencil braces. Tighten the bolts to 105 in. lbs. (12 N.m).
157. Connect the engine harness to the MAP sensor.
158. Connect the engine harness to the throttle body.
159. Install brake booster and other vacuum lines to the intake manifold.
160. Install the EGR tube and new gasket to the EGR valve. Finger-start the bolts (Figure 38).
161. Install the EGR tube into the intake manifold (Figure 38).
162. Align the EGR tube and tighten the flange bolts at the intake manifold to 95 in. lbs. (11 N.m).
163. Tighten the two EGR tube bolts at the EGR valve to 95 in. lbs. (11 N.m).
164. Install PCV hose.
165. Install the engine air inlet filter box.
166. Install the connecting tube between the air inlet filter box and the throttle body.
167. Install the strut tower structural bar to the right and left strut towers.
168. Install cowl grill.
169. Install cowl grill push pins.
170. Inspect the dipstick tube "O" ring for damage. If damaged, install a new "O" ring (PN 05003905AA).
171. Install the dipstick tube into the oil pan.
172. Install the dipstick tube mounting bolt and tighten to 30 ft. lbs. (41 N.m).
173. Install the generator upper support bracket to the generator. Tighten the generator bolt to 48 ft. lbs. (65 N.m) and the engine block bolt to 40 ft. lbs. (54 N.m).
174. Install the engine dipstick.
175. Install six new quarts of 10W30 engine oil.
176. Install coolant into the cooling system.
177. Install radiator cap.
178. Connect the battery.
179. Verify the seating of the cargo floor panel.
180. Start the vehicle and inspect for leaks.
181. Evacuate and charge the air conditioning system.
182. Return vehicle to the customer.