Engine Mount Replacement - Left Side

Single Use Fasteners and Components Exhaust Manifold Bolt [5x] Exhaust Manifold Gasket Exhaust System Seal Special Tools EN-36857 Engine Lift Bracket EN-52059 Engine Support Fixture Adaptor Bolt - M10 Equivalent regional tools: Special Tools

Caution

Broken engine mountings can cause misalignment of certain drive-train components. Misalignment of drive-train components causes eventual destruction of the drive-train components. If one engine mount breaks, the rest of the engine mounts will have increased stress put on them. This could cause the rest of the engine mounts to break.

Warning

In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

Warning

Avoid contact with HOT components. Wear safety glasses and protective gloves to avoid personal injury. Removal Procedure

1. Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection
2. Front Wheelhouse Liner » Remove — Front Wheelhouse Liner Replacement

Engine Mount Replacement - Left Side — figure 1

3. Disconnect the heated oxygen sensor electrical connector.

Caution

Refer to Heated Oxygen and Oxygen Sensor Caution.

Note

The heated oxygen sensor in-line connector and louvered end MUST be kept clear of all grease, dirt, and other contaminants. Do NOT use cleaning solvents of any type. Do NOT drop or roughly handle the sensor. The heated oxygen sensor MAY be difficult to remove when the engine temperature is less than 48°C (120°F).

4. Remove the heated oxygen sensor (1) using a suitable tool.

Engine Mount Replacement - Left Side — figure 2

5. Exhaust Heat Shield Bolt (1) » Remove
6. Exhaust Front Pipe Heat Shield (2) » Remove

Engine Mount Replacement - Left Side — figure 3

7. Exhaust Front Pipe Nut - Left Side (1) » Remove [3x]
8. Lower the vehicle.

Engine Mount Replacement - Left Side — figure 4

9. Mid Intermediate Steering Shaft Bolt (1) » Remove

Engine Mount Replacement - Left Side — figure 5

10. Upper Intermediate Steering Shaft (1) @ Intermediate Steering Shaft » Separate

Engine Mount Replacement - Left Side — figure 6

Note

Pull only on the spark plug wire boot to remove the wire.

11. Spark Plug Wire - Left Side (1) @ Gas Engine Ignition Spark Plug (2) » Remove and position aside [4x]

Engine Mount Replacement - Left Side — figure 7

12. Remove the 3 left side exhaust manifold heat shield bolts (1) through the wheel opening.

Engine Mount Replacement - Left Side — figure 8

13. Exhaust Manifold Heat Shield - Left Side (1) » Remove

Engine Mount Replacement - Left Side — figure 9

14. Exhaust Manifold Bolt (1) » Remove and DISCARD [5x]

Engine Mount Replacement - Left Side — figure 10

15. Exhaust Manifold - Left Side (1) » Remove
16. Exhaust Manifold Gasket (2) » Remove and DISCARD

Engine Mount Replacement - Left Side — figure 11

17. Exhaust System Seal (1) » Remove and DISCARD

Engine Mount Replacement - Left Side — figure 12

Note

Work through the front wheelhouse opening to access the 3 engine mount frame side bolts  (1).

18. Engine Mount Frame Side Bolt - Left Side (1) » Remove [3x]

Engine Mount Replacement - Left Side — figure 13

19. Install the EN-36857 Engine Lift Bracket (1) to the front of the left side cylinder head as shown using the EN-52059 Engine Support Fixture Adaptor Bolt - M10.

Caution

When raising or supporting the engine for any reason, do not use a jack under the oil pan, any sheet metal, or the crankshaft pulley. Lifting the engine in an unapproved manner may cause component damage.

Note

When raising the engine only raise the engine enough to separate the engine mount from the engine mount bracket. Raising any further will require removal of the fan shroud or the exhaust pipe.

20. Raise the engine using a suitable lifting device to remove the engine mount.

Engine Mount Replacement - Left Side — figure 14

Note

Work through the front wheelhouse opening to access the 4 engine mount engine side bolts (1).

21. Engine Mount Engine Side Bolt - Left Side (1) » Remove [4x]

Engine Mount Replacement - Left Side — figure 15

22. Engine Mount - Left Side (1) » Remove Cleaning and Inspection Procedure - Conditional

Note

The following cleaning and inspection and/or overhaul steps are ONLY to be performed as determined necessary based on the condition of the part being removed with the intention of reinstallation. The labor time to perform any of these steps is not included in the base labor time and if required would need to be documented and submitted as Other Labor Hours for warranty claim reimbursement. A description of the repairs performed must be documented in the technician correction comments.

Engine Mount Replacement - Left Side — figure 16

1. Clean the exhaust manifold (1) and heat shield (2) in solvent.
2. Dry the exhaust manifold (1) with compressed air.
3. Inspect the exhaust manifold (1) to the cylinder head exhaust manifold gasket surface for excessive scratches or gouging.
4. Inspect for a loose, damaged, or cracked heat shield (2).
5. Inspect the heat shield bolts (3) for damaged threads.

Engine Mount Replacement - Left Side — figure 17

6. Use a straight edge (1) and a feeler gauge and measure the exhaust manifold cylinder head deck for warpage. An exhaust manifold cylinder head deck with warpage in excess of 0.25 mm (0.01 in) within the 2 front or 2 rear runners or 0.5 mm (0.02 in) overall, may cause an exhaust leak. Exhaust manifolds not within specifications MUST be replaced.

Note

Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation.

7. Inspection the spark plug wire for the following conditions: 7.1. Correct routing of the spark plug wires. Incorrect routing may cause cross-firing. 7.2. Inspect for any signs of cracks or splits in the wires.

8. Inspect each boot for the following conditions: 8.1. Tearing 8.2. Piercing 8.3. Arcing 8.4. Carbon tracking 8.5. Corroded terminals

9. If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or on a terminal, replace the wire and the component connected to the wire. Installation Procedure

10. Engine Mount - Left Side (1) » Install

11. Prepare the 4 engine mount engine side bolts for installation as follows: 2.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 2.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 2.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 2.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

12. Engine Mount Engine Side Bolt - Left Side (1) » Install and hand tighten [4x]

Caution

Refer to Fastener Caution.

4. Engine Mount Engine Side Bolt - Left Side (1) » Tighten [4x] — Fastener Specifications

5. Lower the engine.

6. Prepare the 3 engine mount frame side bolts for installation as follows: 6.1. Remove any loose cured adhesive from the external threads of the component using a lint free cloth. 6.2. Thread the cleaned component into the internal mating threads and remove to loosen trapped cured adhesive. 6.3. Apply thread locking adhesive to the external threads of the component. Adhesives, Fluids, Lubricants, and Sealers 6.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

7. Engine Mount Frame Side Bolt - Left Side (1) » Install and hand tighten [3x]

8. Engine Mount Frame Side Bolt - Left Side (1) » Tighten in sequence [3x] — Fastener Specifications

9. Remove the EN-52059 Engine Support Fixture Adaptor Bolt - M10 and EN-36857 Engine Lift Bracket (1) from the front of the left side cylinder head.

10. Exhaust System Seal (1) » Install NEW

11. Exhaust Manifold Gasket (2) » Install NEW

12. Exhaust Manifold - Left Side (1) » Install

13. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps: 13.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 13.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 13.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 13.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

14. Exhaust Manifold Bolt (1) » Install NEW and tighten in sequence [5x] — Fastener Specifications

15. Exhaust Manifold Heat Shield - Left Side (1) » Install

16. Through the wheel opening, install and tighten the 3 left side exhaust manifold heat shield bolts (1). Fastener Specifications

17. Inspect the inside of the 4 spark plug rubber boots for a thin, even coat of grease. If there is no grease present or additional grease is necessary, apply a thin coating of dielectric grease evenly to the inside of the 4 spark plug rubber boots up to a depth of 15 mm (0.59 in) from the end of the boots. Adhesives, Fluids, Lubricants, and Sealers.

18. Push the boot of the 4 spark plug wires (1) onto the 4 gas engine ignition spark plugs (2) until 2 audible clicks are heard.

19. Upper Intermediate Steering Shaft (1) @ Intermediate Steering Shaft » Install

20. If a NEW threaded component is being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded component is reused, prepare the threaded component using the following steps: 20.1. Remove any loose cured adhesive from the external threads of the component using a lint free cloth. 20.2. Thread the cleaned component into the internal mating threads and remove to loosen trapped cured adhesive. 20.3. Apply thread locking adhesive to the external threads of the component. Adhesives, Fluids, Lubricants, and Sealers 20.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

21. Mid Intermediate Steering Shaft Bolt (1) » Install and tighten — Fastener Specifications

22. Exhaust Front Pipe Nut - Left Side (1) » Install and tighten [3x] — Fastener Specifications

23. Exhaust Front Pipe Heat Shield (2) » Install

24. Exhaust Heat Shield Bolt (1) » Install and tighten — Fastener Specifications

Note

A special anti-seize compound is used in the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before reinstallation. Adhesives, Fluids, Lubricants, and Sealers

Caution

Refer to Component Fastener Tightening Caution.

25. Install and tighten the heated oxygen sensor (1) using a suitable tool. Fastener Specifications
26. Connect the heated oxygen sensor electrical connector.
27. Front Wheelhouse Liner » Install — Front Wheelhouse Liner Replacement
28. Lower the vehicle.
29. Connect the battery negative cable. Battery Negative Cable Disconnection and Connection
30. Start the engine and check for exhaust leaks.