Engine Mount Replacement - Right Side (1)

Engine Mount Replacement - Right Side Single Use Fasteners and Components Exhaust Manifold Bolt [5x] Exhaust Manifold Gasket Exhaust System Seal Oil Level Indicator Seal Special Tools EN-36857 Engine Lift Bracket EN-51768 Engine Support Fixture Adaptor Bolt - M8 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

Engine Mount Replacement - Right Side (1) — figure 1

2. Remove the oil level indicator. (1)

Engine Mount Replacement - Right Side (1) — figure 2

3. Oil Level Indicator Tube Bolt (1) » Remove
4. Front Wheelhouse Liner - Right Side » Remove — Front Wheelhouse Liner Replacement

Engine Mount Replacement - Right Side (1) — figure 3

5. Engine Wiring Harness Retainer (1) @ Oil Level Indicator Tube (2) » Disconnect
6. Engine Wiring Harness (3) » Reposition

Engine Mount Replacement - Right Side (1) — figure 4

7. Oil Level Indicator Tube (1) @ Oil Pan » Remove
8. Oil Level Indicator Tube (1) » Remove
9. Oil Level Indicator Seal (2) » Remove and DISCARD
10. Wiring Harness » Position aside

Engine Mount Replacement - Right Side (1) — figure 5

11. Exhaust Manifold Heat Shield Bolt - Right Side (1) » Remove [3x]

Engine Mount Replacement - Right Side (1) — figure 6

12. Remove the right exhaust manifold heat shield (1) through the wheel opening.

Engine Mount Replacement - Right Side (1) — figure 7

13. Exhaust Heat Shield Bolt (1) » Remove
14. Exhaust Front Pipe Heat Shield - Right Side (2) » Remove

Engine Mount Replacement - Right Side (1) — figure 8

15. Disconnect the heated oxygen sensor electrical connector.

Engine Mount Replacement - Right Side (1) — figure 9

16. Exhaust Front Pipe Nut - Right Side (1) » Remove [3x]

Engine Mount Replacement - Right Side (1) — figure 10

Note

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

Note

Inspect the spark plug wire for damage and replace if necessary.

17. Twist the 4 spark plug wire boots a ½ turn and remove the 4 spark plug wires (1) from the 4 gas engine ignition spark plugs (2).

Engine Mount Replacement - Right Side (1) — figure 11

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

Engine Mount Replacement - Right Side (1) — figure 12

19. Remove the right side exhaust manifold (1) through the wheel opening.
20. Exhaust Manifold Gasket - Right Side (2) » Remove and DISCARD

Engine Mount Replacement - Right Side (1) — figure 13

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

Engine Mount Replacement - Right Side (1) — figure 14

Note

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

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

Engine Mount Replacement - Right Side (1) — figure 15

23. Install EN-36857 Engine Lift Bracket (1) to the front of the right side cylinder head as shown using EN-51768 Engine Support Fixture Adaptor Bolt - M8.

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 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.

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

Engine Mount Replacement - Right Side (1) — figure 16

Note

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

25. Engine Mount Engine Side Bolt - Right Side (1) » Remove [4x]

Engine Mount Replacement - Right Side (1) — figure 17

26. Engine Mount - Right 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 - Right Side (1) — figure 18

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 - Right Side (1) — figure 19

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 - Right Side (1) » Install

11. Prepare the 4 engine mount engine side bolts (1) 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 - Right Side (1) » Install and hand tighten [4x]

Caution

Refer to Fastener Caution.

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

5. Lower the engine.

6. Prepare the 3 engine mount frame side bolts (1) for installation as follows: 6.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 6.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 6.3. Apply thread locking adhesive to the external threads of the components. 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 - Right Side (1) » Install and hand tighten [3x]

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

9. Remove the EN-51768 Engine Support Fixture Adaptor Bolt - M8 and EN-36857 Engine Lift Bracket (1) from the front of the right side cylinder head.

10. Exhaust System Seal (1) » Install NEW

11. Exhaust Manifold Gasket - Right Side (2) » Install NEW

12. Install the right side exhaust manifold (1) through the wheel opening.

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 - Right Side (1) » Install NEW and tighten in sequence [5x] — Fastener Specifications

Engine Mount Replacement - Right Side (1) — figure 20

15. 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 from the end of the boot. Adhesives, Fluids, Lubricants, and Sealers

16. 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.

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

18. Connect the heated oxygen sensor electrical connector.

19. Exhaust Front Pipe Heat Shield - Right Side (2) » Install

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

21. Install the right exhaust manifold heat shield (1) through the wheel opening.

22. Exhaust Manifold Heat Shield Bolt - Right Side (1) » Install and tighten [3x] — Fastener Specifications

23. Wiring Harness » Reposition

24. Oil Level Indicator Seal (2) » Install NEW

25. Lubricate the NEW oil level indicator seal (2) with clean engine oil. Adhesives, Fluids, Lubricants, and Sealers

26. Oil Level Indicator Tube (1) @ Oil Pan » Install

27. Engine Wiring Harness (3) » Install

28. Engine Wiring Harness Retainer (1) @ Oil Level Indicator Tube (2) » Connect

29. Front Wheelhouse Liner - Right Side » Install — Front Wheelhouse Liner Replacement

30. Oil Level Indicator Tube Bolt (1) » Install and tighten — Fastener Specifications

31. Install the oil level indicator. (1)

32. Connect the battery negative cable. Battery Negative Cable Disconnection and Connection

33. Start the engine and check for exhaust leaks.