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Section 4 (5.7L Engine (Service Information)): Installation: Installation

WARNING: This page is about a different variant/trim than selected.
CAUTION:

If the original engine has experienced a catastrophic failure or an individual failure with the piston, cylinder bore, engine block, valve or valve seat, the intake manifold MUST be replaced with a new manifold.

Fig 1: Engine Lift Fixture & Mounting Bolts
GC0146152Courtesy of CHRYSLER GROUP, LLC
NOTE:

Do not use air tools to install Engine Lift Fixture (special tool #8984B, Fixture, Engine Lifting) (1).

  1. Install the Engine Lift Fixture (special tool #8984B, Fixture, Engine Lifting) (1).
  2. Connect a suitable engine lifting devise to the Engine Lift Fixture (special tool #8984B, Fixture, Engine Lifting) (1).
  3. Position the engine in the vehicle.
    Fig 2: Removing/Installing Transmission to Engine Bolts
    GC0081756Courtesy of CHRYSLER GROUP, LLC
  4. Lower and align the engine (1) with the transmission (3).
  5. Continue to lower the engine assembly until the engine mounting brackets lineup with the engine mounts.
  6. Install two transmission to engine block mounting bolts (2) finger tight.
  7. Remove the engine lifting devise.
  8. Raise and support the vehicle.
    Fig 3: Rear Engine Mount Isolator, Transmission Crossmember Support Brackets & Bolts
    GC0146187Courtesy of CHRYSLER GROUP, LLC

    4x4 rear engine mount isolator shown in illustration, 4x2 rear engine mount isolator similar. 

  9. Using a suitable transmission hydraulic jack, slightly raise the transmission and remove the block of wood between the transmission and engine cradle crossmember, lower the transmission and remove the jack.
  10. Tighten the rear engine mount isolator retaining bolts (1) to 61 N.m (45 ft. lbs.).
    Fig 4: Remove/Install Transmission To Engine Bolts
    GC0082900Courtesy of CHRYSLER GROUP, LLC
  11. Install the remaining transmission bell housing-to-engine block retaining bolts (2) and tighten to 68 N.m (50 ft. lbs.).
    Fig 5: Flexplate/Torque Converter Retaining Bolts
    GC0146194Courtesy of CHRYSLER GROUP, LLC
  12. Install all torque converter-to-flexplate bolts (1) finger tight.
  13. Verify the torque converter is pulled flush to the flexplate and tighten bolts to 31 N.m (23 ft. lbs.).
    Fig 6: Engine Mount & Retaining Nut
    GC0146153Courtesy of CHRYSLER GROUP, LLC

    Left side shown in illustration, right side similar. 

  14. Install the engine mount retaining nuts (2) and tighten to 95 N.m (70 ft. lbs.).
    Fig 7: Structural Dust Cover & Retaining Bolts
    GC0145663Courtesy of CHRYSLER GROUP, LLC
    CAUTION:

    The structural dust cover must be installed as described in the following steps. Failure to do so may cause severe damage to the cover.

  15. Position the structural cover (2) in the vehicle.
  16. Install the structural dust cover bolts (1) to the engine block finger tight.
  17. Install the structural dust cover bolts (1) to the transmission finger tight.
    CAUTION:

    The structural dust cover must be held tightly against both the engine and the transmission bell housing during the tightening sequence. Failure to do so may cause severe damage to the cover.

  18. Tighten the structural dust cover bolts to the transmission to 9 N.m (80 in. lbs.).
  19. Tighten the structural dust cover bolts to the engine block to 9 N.m (80 in. lbs.).
  20. Again, tighten the structural dust cover bolts to the transmission to 54 N.m (40 ft. lbs.).
  21. Again, tighten the structural dust cover bolts to the engine block to 54 N.m (40 ft. lbs.).
    Fig 8: Engine Lift Fixture & Mounting Bolts
    GC0146152Courtesy of CHRYSLER GROUP, LLC
  22. Lower the vehicle.
  23. Remove the Engine Lift Fixture (special tool #8984B, Fixture, Engine Lifting) (1).
  24. Position the engine harness on both right and left sides of the vehicle.
    Fig 9: Oil Control Valve, Electrical Connector & Retaining Bolt
    GC0144407Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    Ensure that the O-ring is fully seated into the cylinder block.

  25. Position the oil control valve (3) into the cylinder block.
  26. Securely tighten the oil control valve retaining bolt (2).
  27. Connect the oil control valve electrical connector (1).
  28. Install the intake manifold. Refer to MANIFOLD, INTAKE, REMOVAL, 5.7L  .
    Fig 10: Cooling Fan Module Components
    GC0144321Courtesy of CHRYSLER GROUP, LLC
  29. Install the generator. Refer to GENERATOR, INSTALLATION .
  30. Install the cooling fan module (1). Refer to FAN, COOLING, REMOVAL .
    Fig 11: Heater Hoses & Clamps
    GC0146186Courtesy of CHRYSLER GROUP, LLC
  31. Position both heater hoses (2).
  32. Install both heater hose clamps (1).
    Fig 12: Upper Radiator Hose Clamp & Retainer
    GC0145666Courtesy of CHRYSLER GROUP, LLC
  33. Position the upper radiator hose and secure the retainer (2) at the fan shroud.
  34. Connect the upper radiator hose to the thermostat housing and install the hose clamp (1).
  35. Raise and support the vehicle.
    Fig 13: Starter Motor & Bolts
    GC0104231Courtesy of CHRYSLER GROUP, LLC
  36. Install the starter (1). Refer to STARTER, REMOVAL .
  37. Install the A/C compressor to the engine block. Refer to COMPRESSOR, A/C, INSTALLATION .
  38. Connect the transmission oil cooler lines to their retainer at the oil pan.
    Fig 14: Heat Shield & Retaining Bolts
    GC0146154Courtesy of CHRYSLER GROUP, LLC
  39. Install both exhaust pipe/catalytic converters. Refer to CONVERTER, CATALYTIC, INSTALLATION .
  40. Position the left catalytic converter heat shield (2) install the retaining bolts (1) and securely tighten.
    Fig 15: Lower Radiator Hose & Clamps
    GC0146185Courtesy of CHRYSLER GROUP, LLC
  41. Connect the lower radiator hose (3) to the radiator and install the hose clamp (2).
  42. Connect the lower radiator hose to the water pump and install hose clamp (1).
    Fig 16: Skid Plate & Retaining Bolts
    GC0095646Courtesy of CHRYSLER GROUP, LLC
  43. If equipped, position the skid plate, install the four retaining bolts (2) and tighten to 28 N.m (21 ft. lbs.).
  44. Lower the vehicle.
    Fig 17: Left Upstream O2 Sensor & Electrical Connector
    GC0146182Courtesy of CHRYSLER GROUP, LLC
  45. Connect the left upstream 02 sensor electrical connector (1).
    Fig 18: Right Upstream O2 Sensor & Electrical Connector
    GC0146183Courtesy of CHRYSLER GROUP, LLC
  46. Connect the right upstream 02 sensor electrical connector (1).
  47. Connect all remaining left and right engine harness electrical connectors.
    Fig 19: Power Steering Pump & Return Hose
    GC0118699Courtesy of CHRYSLER GROUP, LLC
  48. Install the power steering pump (1). Refer to PUMP, INSTALLATION .
  49. Install the serpentine belt. Refer to BELT, SERPENTINE, INSTALLATION .
    Fig 20: Cowl Panel Cover, Guide Pin, Tabs & Clips
    GC0146023Courtesy of CHRYSLER GROUP, LLC
  50. Install the cowl panel cover (2). Refer to COVER, COWL PANEL, INSTALLATION .
  51. Start the engine and inspect for leaks.
  52. Install the air cleaner and resonator assembly. Refer to BODY, AIR CLEANER, INSTALLATION, 5.7L  .
    Fig 21: Negative Battery Cable
    GC0145484Courtesy of CHRYSLER GROUP, LLC
  53. Fill the engine with oil. Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
  54. Fill the cooling system. Refer to STANDARD PROCEDURE .
  55. Connect the negative battery cable (2).
    Fig 22: Oil Fill Cap & Engine Cover
    GC0143807Courtesy of CHRYSLER GROUP, LLC
  56. Install the engine cover (2).
  57. Install the oil fill cap (1).
  58. Start the engine and check for leaks.
  59. Road test vehicle.
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