Installation Procedure

Engine Replacement

Tools Required

EN 46114 Engine Lifting Brackets

Installation Procedure

1. Use a floor crane in order to install the engine to the frame.
2. Install the engine mount brackets with the engine mounts. Refer to Engine Mount Bracket Replacement - Left Side (Service and Repair) and Engine Mount Bracket Replacement - Right Side (Service and Repair) .
3. Raise the floor crane to partially support the engine
4. Install the alternator bracket. Refer to Generator Bracket Replacement (3.6L Engine) (Generator Bracket Replacement (3.6L Engine))Generator Bracket Replacement (6.0L Engine) (Generator Bracket Replacement (6.0L Engine)) .
5. Install the alternator. Refer to Generator Replacement (3.6L Engine) (Generator Replacement (3.6L Engine))Generator Replacement (6.0L Engine) (Generator Replacement (6.0L Engine)) .
6. Install the A/C compressor mounting bracket. Refer to Air Conditioning Compressor Bracket Replacement (3.6L Engine) (Service and Repair) .
7. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement (3.6L Engine) (Service and Repair)Air Conditioning Compressor Replacement (6.0L Engine) (Service and Repair) .




8. Install the power steering pump (1) to the power steering pump bracket (2).

Notice: Refer to Fastener Notice (Fastener Notice) .

9. Install the NEW power steering pump to power steering pump bracket retaining bolts (3).

Tighten the bolts to 27 N.m (22 lb ft).






Important: Make sure the power steering reservoir (2) and the power steering reservoir bracket locking tang (1) are engaged to avoid an induced rattle condition.


10. Install the power steering fluid reservoir to the power steering fluid reservoir bracket.
11. Install the drive belt. Refer to Drive Belt Replacement (Service and Repair) .
12. Install the catalytic converters. Refer to Catalytic Converter Replacement - Left Side (6.0L Engine) (Catalytic Converter Replacement - Left Side (6.0L Engine))Catalytic Converter Replacement - Left Side (3.6L Engine) (Catalytic Converter Replacement - Left Side (3.6L Engine)) and Catalytic Converter Replacement - Right Side (6.0L Engine) (Catalytic Converter Replacement - Right Side (6.0L Engine))Catalytic Converter Replacement - Right Side (3.6L Engine) (Catalytic Converter Replacement - Right Side (3.6L Engine)) .
13. Install the flywheel. Refer to Engine Flywheel Removal (Overhaul) .
14. Install the transmission. Refer to Transmission Replacement (Removal and Replacement) in Automatic Transmission - 5L40-E/5L50-E.




15. Install the transmission cooler line clamp (3) and transmission cooler lines (2) to the alternator mounting bracket (4).
16. Install the transmission cooler line clamp to alternator mounting bracket retaining nut (1).

Tighten the nut to 22 N.m (16 lb ft).

17. Install the engine and transmission wiring harness and related components. Refer to Engine Wiring Harness Assembly Removal (Overhaul) .




18. Remove the EN 46114 (2) on the engine (1).

Important: Make sure that all the hoses, wires, pipes and shock modules clear the vehicle during the installation process.


19. With the aid of an assistant, raise the table and/or lower the vehicle to install the engine, transmission, front suspension and subframe assembly to the vehicle.




20. Install the transmission support to body retaining bolts (1).

Tighten the bolts to 58 N.m (43 lb ft).





21. Install the subframe to body retaining bolts (1).

Tighten the bolts to 160 N.m (118 lb ft).





22. Install the subframe to body front retaining bolts (1).

Tighten the bolts to 160 N.m (118 lb ft).





23. Install the subframe to body rear retaining bolts (1).

Tighten the bolts to 240 N.m (177 lb ft).





24. Install the subframe reinforcement plate (3) to the subframe (1).
25. Install the subframe reinforcement plate to subframe retaining bolts (2).

Tighten the bolts to 17 N.m (13 lb ft).

26. Lower the lift table and/or raise the vehicle to remove the support from the frame, engine and transmission.
27. Remove the powertrain and/or engine lift table from the frame, engine and transmission.
28. Partially lower the vehicle.





Notice: Refer to Fastener Notice (Fastener Notice) .


Important: The strut assembly retaining nut (1) must be checked for correct torque before installing the strut assembly into the vehicle. The strut assembly retaining nut torque must be 75 N.m (55 lb ft).


29. Check the torque of the strut assembly retaining nut (1), correct if necessary.




30. Install the strut assembly (3) to the vehicle (4).
31. Install strut assembly to body retaining plate (1).
32. Tighten the NEW strut assembly to body retaining nut (2).

Tighten the nut to 55 N.m (40 lb ft).





33. Install the dust cover (1) to the strut assembly to body retaining nut (2).
34. Partially raise the vehicle.




35. Remove the heavy mechanics wire or equivalent (2) retaining the strut assembly (1) to the subframe (3).





Important: The intermediate steering shaft and pinion shaft splines must be installed in the position recorded during removal and aligned with the marks previously made.


36. Connect the intermediate steering shaft (1) to the pinion shaft (3).
37. Install NEW the intermediate steering shaft to pinion shaft retaining bolt (2).

Tighten the bolt to 25 N.m (18 lb ft).





38. Connect the wheel speed sensor jumper harness electrical connector (1).




39. Remove the heavy mechanic's wire, or equivalent support (2) from the brake caliper (1).
40. Remove the wheel nuts (4) retaining the brake disc (3) to the hub (5).





Notice: Make sure the brake hose is not twisted or kinked after installation. Damage to the hose could result.

41. Install the brake caliper assembly (2) to the steering knuckle (3).
42. Install the NEW brake caliper anchor plate to knuckle retaining bolts (1).

Tighten to 60 N.m +120° (44 lb in +120°).






Notice: Make sure the brake hose is not twisted or kinked after installation. Damage to the hose could result.

43. Attach the brake hose (1) to the strut mounted brake hose retaining bracket (2).
44. Install the front wheels. Refer to Tire and Wheel Removal and Installation (Service and Repair) .




45. Install the shift selector linkage rod (1) to the shift selector shaft (2).
46. Install the shift selector linkage rod to shift selector shaft retaining nut (3).

Tighten the nut to 9 N.m (80 lb in).

47. Install the starter motor. Refer to Starter Motor Replacement (3.6L Engine) (Starter Motor Replacement (3.6L Engine))Starter Motor Replacement (6.0L Engine) (Starter Motor Replacement (6.0L Engine)) .
48. Install the propeller shaft. Refer to Propeller Shaft Replacement (Propeller Shaft Replacement) .
49. Install the centre exhaust heat shield. Refer to Exhaust Heat Shield Replacement - Center (Exhaust Heat Shield Replacement - Center) .
50. Install the Exhaust system. Refer to Exhaust System Replacement (LY7) (Exhaust System Replacement)Exhaust System Replacement (L98) (Exhaust System Alignment) .




51. Connect the low oil level sensor electrical connector (1).




52. Remove the plug from the power steering cooler (3) and power steering reservoir inlet hose (2).
53. Connect the power steering reservoir inlet hose (2) to the power steering cooler (3).
54. Install the power steering reservoir inlet hose spring clamp (1) to its original location




55. Remove the plug from the power steering cooler (3) and power steering reservoir inlet hose (1).
56. Connect the power steering reservoir inlet hose (1) to the power steering cooler (3).
57. Install the power steering reservoir inlet hose spring clamp (2) to its original location
58. Install the engine splash shield. Refer to Engine Splash Shield Replacement (Service and Repair) .
59. Install the front air deflector. Refer to Front Air Deflector Replacement (Service and Repair) .
60. Lower the vehicle.




61. Remove the zip ties (2) or equivalent securing the radiator and condenser assembly (3) to the front end assembly (1).





Important: The AU-525 is not required for installation.


62. Remove the clean lint free cloth at the transmission cooler lines (2) and the flexible hoses (1).

Important: The flexible hoses are not serviced separately. Therefore if the hose's require replacement, then the hose and radiator to hose cooler hose assembly must be fitted.


63. Align both flexible hose's with both steel cooler lines.

Important: Listen for an audible click to confirm fitting.


64. Hold the cooler line (2) and connect the flexible hose (1) by pushing together. Repeat procedure for other hose.

Important: When adding or changing transmission fluid use only recommended automatic transmission fluid.


65. Check and top up transmission fluid level if required.




66. Remove the plug or cap at the fuel feed hose (1) and fuel feed pipe (2) ends.
67. Connect the fuel feed hose (1) to the fuel feed pipe (2). Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service) or Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service) .
68. Remove the plug or cap at the EVAP purge line (4) and the purge solenoid (3) ends.
69. Connect the EVAP purge line (4) to the purge solenoid (3). Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service) or Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service) .





Important: DO NOT coat the new sealing washer with oil. They must be fitted dry. The use of mineral oil will render the washer useless, as the washer WILL swell causing refrigerant to leak out.


70. Install a NEW sealing washer (3) to suction pipe joint.
71. Position the upper suction pipe (1) to the lower suction pipe (2).




72. Install the A/C suction pipe pad to A/C suction pipe retaining nut (1).

Tighten the nut to 22 N.m( 16 lb ft).





73. Remove the plug or cap at the A/C suction/discharge pipe (1) ends and the compressor (2) ports.

Important: The A/C sealing O-rings must be fitted dry. DO NOT lubricate the A/C sealing O-rings.


74. Fit the NEW A/C suction/discharge pipe sealing O-ring (2) to the suction pipe.
75. Connect the A/C suction/discharge line pad (1) to the A/C compressor (2).




76. Install the suction/discharge line pad to A/C compressor retaining nut (1).




77. Connect the A/C compressor electrical connector (1).




78. Connect the A/C pressure transducer electrical connector (1).




79. Install the wiring harness (2).
80. Install the remote battery positive post to wiring harness retaining bolt (1).

Tighten the bolt to 15 N.m (11 lb ft).






Important: Make sure the clips on the remote battery positive post cover (1) are engaged to avoid an induced rattle condition.


81. Install the remote battery positive post cover (1).




82. Connect the vehicle body ground cable (1) to the cylinder head (2).
83. Install the vehicle body ground cable to the cylinder head retaining bolt (3)

Tighten the bolt to 10 N.m(89 lb in).






Important: Listen for a audible click from the locking tang (2) to confirm fitting.


84. Slide the engine connector (3) into the body harness connector (1) to join.




85. Attach the protector (1) to the base of the under hood BEC connector (2).




86. Install the upper under hood BEC plate (1) to the lower under hood BEC plate (3).

Important: The under hood BEC upper plate to lower plate retaining bolts (2) DO NOT have a torque specification. Listen for an audible clicking sound whilst tightening the under hood BEC upper plate to lower plate retaining bolts (2) to confirm correct fitting.


87. Install the under hood BEC upper plate to lower plate retaining bolts (2).




88. Connect the positive cable (2) to the upper under hood BEC plate (4).
89. Install the positive cable to under hood BEC plate retaining bolt (5).

Tighten the bolt to 10 N.m(89 lb ft).

90. Install the positive cable protective cover (3).
91. Install the under hood body electrical centre (BEC) lid (1).




92. Connect the 56 pin engine wiring harness to main wiring harness electrical connector (1).
93. Connect the 2 pin engine wiring harness to main wiring harness electrical connector (2).




94. Connect ECM electrical connectors (2).
95. Rotate the engine control module (ECM) electrical connector levers (1) to the locked position.
96. Install the engine coolant heater cord if fitted. Refer to Coolant Heater Cord Replacement (3.6L Engine) (Coolant Heater Cord Replacement (3.6L Engine))Coolant Heater Cord Replacement (6.0L Engine) (Coolant Heater Cord Replacement (6.0L Engine)) .




97. Connect the vacuum hose (1) to the intake manifold vacuum port (3).
98. Compress the vacuum hose retaining clamp (2) and slide along the vacuum hose (1) to the correct location to secure the vacuum hose (1) to the intake manifold vacuum port (3).




Caution: Refer to Installing Hoses without Twists or Bends Notice (Installing Hoses without Twists or Bends Notice) .

Important: Listen for a audible click to confirm fitting in two places


99. Attach the heater hose (1) quick connect fitting (3) by pushing the hose onto the heater pipe (2).




100. Remove the plug or cap at the cooling system hoses and inlets
101. Install the coolant bleed hose (3) to the outlet housing (1).
102. Compress the coolant bleed hose retaining clamp (4) and position back to its original location on the coolant bleed hose (3).
103. Connect the coolant recovery hose (2) from the outlet housing (1).
104. Install the radiator outlet hose. Refer to Radiator Outlet Hose Replacement (3.6L Engine) (Service and Repair)Radiator Outlet Hose Replacement (6.0L Engine) (Service and Repair) .
105. Connect the battery ground cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair) .
106. Refill the cooling system. Refer to Cooling System Draining and Filling (Service and Repair) .
107. Install the air intake duct. Refer to Air Cleaner Inlet Duct Replacement (Service and Repair) .
108. Recharge the air conditioning (A/C) system. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging) .
109. Install the radiator air intake baffle. Refer to Radiator Air Upper Baffle and Deflector Replacement (Service and Repair) .
110. Install the engine covers. Refer to Engine Cover Replacement (Service and Repair) .
111. Disable the ignition system.
112. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
113. Enable the ignition system.
114. Start the engine and listen for unusual noises.
115. 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.
116. Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.
117. Listen for sticking stationary hydraulic lash adjuster, (SHLAs) (valve lifters) and other unusual noises.
118. Inspect for fuel, oil, and/or other coolant leaks while the engine is running.