Installation Procedure
- Prepare the engine for installation.
- If replacing the engine, transfer components as necessary.
- Install the J-41803-9 engine lift hooks to the engine.
- Using an engine hoist and the J-41803-9 engine lift hooks raise the engine slightly.
- Remove the engine from the engine stand.
- Using an engine hoist and the J-41803-9 engine lift hooks lower the engine onto the cradle.
- Install the engine mount nuts and tighten to 65 N.m (48 lb ft).
- Remove the J 41798 engine lifting brackets from the engine.
- Position the engine and cradle beneath the vehicle.
- Partially lower the vehicle onto the engine and cradle.
- Route the ground harness and install retaining fasteners at the left and right rear cylinder heads. Tighten the fasteners to 10 N.m (89 lb in).
- Route the engine harness and install retaining fasteners at the rear of the engine. Tighten the fasteners to 10 N.m (89 lb in).
- Install the ground straps and ground strap bolts to the rear of cylinder heads. Tighten the ground strap bolts to 32 N.m (24 lb ft).
- Reconnect the electrical connector for the knock sensor, left side.
- Reconnect the electrical connector for the knock sensor, right side.
- Lower the vehicle onto the cradle and align the dowels.
- Install the front and rear cradle fasteners. Drivetrain and Front Suspension Cradle Replacement (LT1, LT4)
- Remove the J 39580 engine support table and the J 39580-500 engine support table top.
- Position harness as needed
- Attach harness retainers and connect electrical connectors as necessary.
Power Brake Booster Inlet Pipe Quick Connect (1) @ Vacuum Pipe - Connect
Transmission Fluid Cooler Pipe Clip Bolt (1) @ Engine Mount - Right Side - Install and tighten - Transmission Fluid Cooler Inlet and Outlet Pipe Replacement (LT1 With M5U, With KNR) , or Transmission Fluid Cooler Inlet and Outlet Pipe Replacement (LT1 With M5U, Without KNR) , or Transmission Fluid Cooler Inlet and Outlet Pipe Replacement (LT4 With MGL and KNR, LT1 With MF6 and KNR)
- Install the lower ball joint in the steering knuckle. [2x] - Front Lower Control Front Link Replacement (LT1, without V18) , or Front Lower Control Front Link Replacement (LT1, LT4, or LTG with 1LE, with V18)
- Steering Linkage Outer Tie Rod @ Steering Knuckle - Connect [2x] - Steering Linkage Outer Tie Rod Replacement
- Stabilizer Shaft Link @ Lower Control Arm - Connect - Stabilizer Shaft Link Replacement (LT1, LT4 or LTG with 1LE)
Oil Level Sensor (3) - Connect
- Crankshaft Position Sensor (2) - Connect
- Knock Sensor (1) - Connect
Starter Solenoid Cable (2) - Install
- Generator Fastener (1) - Install and tighten - Generator Replacement (LT1)
- Electrical Connector (3) - Install
- Transmission - Install - Transmission Replacement (with LT1, LT4)
- Exhaust Muffler - Install - Exhaust Muffler Replacement (LT1, LT4, Coupe) , or Exhaust Muffler Replacement (LT1, LT4, Convertible)
Electrical Connector @ Steering Gear - Connect [2x]
- Connect the intermediate steering shaft to the steering gear. Intermediate Steering Shaft Replacement
- Install the front tires and wheels. Tire and Wheel Removal and Installation
- Front Cradle Shear Plate - Install - Front Cradle Shear Plate Replacement
- Lower the vehicle.
Air Conditioning Compressor Hose - Connect - Air Conditioning Compressor Replacement (LT1)
Fuel Feed Hose (2) @ Fuel Feed Pipe - Connect - Fuel Feed Front Hose Replacement
- Radiator Outlet Hose - Install - Radiator Outlet Hose Replacement (LT1 with V18 V03)
Radiator Inlet Hose (2) @ Engine Coolant Thermostat Housing - Connect
Radiator Surge Tank Inlet Hose (2) @ Engine Coolant Thermostat Housing - Connect
- Recharge the A/C system. Refrigerant Recovery and Recharging (R-134a) , or Refrigerant Recovery and Recharging (R-1234yf)
- If the engine is replaced with a new engine or has been overhauled, perform the Engine Prelubing procedure. Engine Prelubing
- Fill the crankcase with the proper quantity and grade of engine oil. Approximate Fluid Capacities , and Fluid and Lubricant Recommendations
- Disable the ignition system.
- Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
- Enable the ignition system.
- Start the engine and listen for unusual noises.
- Check the vehicle oil pressure gauge and confirm that the engine has acceptable oil pressure.
If necessary, install an oil pressure gauge and measure the engine oil pressure.
- Start the engine and run the engine speed at about 1000 RPM until the engine has reached normal operating temperature.
- Listen for sticking lifters and other unusual noises.
- Inspect for fuel, oil, and/or other coolant leaks while the engine is running.
- Perform the crankshaft position variation learn. Crankshaft Position Variation Learn
- Perform a final inspection for the proper engine oil and coolant levels.
- Align the vehicle. Wheel Alignment Measurement
Refer to Fastener Caution .
Prelube is necessary if the engine is replaced or overhauled.