Installation Procedure

Engine Replacement

Tools Required
* J 38185 Hose Clamp Pliers
* J 39580 Universal Engine Support Table

Installation Procedure




1. Using a suitable engine lift, remove the engine from the engine stand.
2. Position and install the engine to the frame and the transaxle.

Notice: Refer to Fastener Notice (Fastener Notice).

3. Install the transaxle to engine bolts (1) and stud (2).

Tighten the bolts/stud to 75 N.m (55 lb ft).




4. Install the rear engine mount to frame nuts.

Tighten the nuts to 50 N.m (37 lb ft).




5. Install the front engine mount to frame nuts.

Tighten the nuts to 50 N.m (37 lb ft).




6. Ensure that all hoses, wires, and pipes clear the vehicle during the installation process.
7. With the aid of an assistant, raise the J 39580 and/or lower the vehicle to install the engine and frame to the vehicle.
8. Install the engine frame rear bolts.

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




9. Install the engine frame front bolts.

Tighten the bolts to 145 N.m (107 lb ft).




10. Install radiator to front frame brackets.
11. Lower the J 39580, or raise the vehicle to preload the weight of the engine, frame, and front suspension.
12. Remove the support from under the rear of the vehicle.
13. Raise the vehicle enough to remove the J 39580 from under the engine, frame, and front suspension.




14. Connect the exhaust system and connect the O2 sensor harness pigtail. Refer to Catalytic Converter Replacement (Service and Repair).
15. Install the flywheel bolts.

Tighten the bolts to 63 N.m (47 lb ft).




16. Install the converter cover.
17. Install the transaxle converter cover bolt/stud.

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

18. Install the left and right wheel drive shafts into the transaxle. Refer to Wheel Drive Shaft Replacement (Service and Repair).




19. Install the battery cable retainers to the engine frame.
20. Install the front air deflector. Refer to Radiator Air Lower Baffle and Deflector Replacement (Service and Repair).




21. Install the cable ground terminal (6) to the stud.
22. Install the battery cable ground nut (1).

Tighten the nut to 30 N.m (22 lb ft).

23. Install the cable terminal (2) to the starter.
24. Install the positive battery cable nut (3) to the starter.

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




25. Connect the transaxle oil cooler lines to the transaxle. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection (Service and Repair).
26. Install the transaxle oil cooler line bracket bolt/stud.

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




27. Install the power steering hose (2) to the inlet pipe.
28. Tighten the power steering hose clamp at the inlet pipe.

Tighten the clamp to 6 N.m (53 lb in).

29. Connect the power steering pipe to the steering gear. Refer to Power Steering Pressure Pipe/Hose Replacement (LS4) (Power Steering Pressure Pipe/Hose Replacement (LS4)).
30. Connect the power steering pipe to the frame clips.
31. Lower the vehicle.




32. Position and install the ball joint nuts. Refer to Lower Control Arm Ball Joint Replacement (Service and Repair).
33. Install the sway links to the stabilizer shaft. Refer to Stabilizer Shaft Link Replacement (Front Suspension).
34. Install the tie rod ends to the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement (Service and Repair).
35. Connect the wheel speed sensor electrical connectors.
36. Connect the wheel speed sensor wiring harness to the lower control arm.




37. Install the heater inlet (2) and outlet (1) hoses to the heater inlet/outlet pipe.
38. Using the J 38185 position the heater inlet and outlet hose clamps.




39. Install the intermediate shaft to the steering gear.
40. Install the intermediate shaft to steering gear bolt.

Tighten the bolt to 48 N.m (35 lb ft).

41. Position the intermediate shaft lower boot.




42. Route all branches of the engine wiring harness to their correct locations.
43. Connect the engine harness electrical connector to the VSS.




44. Install the VSS shield (2). Install the VSS shield nut (1) and bolt (3).

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




45. Install the shift cable to the bracket.
46. Connect the shift cable to the transaxle selector lever stud.
47. Install the shift cable clip.




48. Install the clip attaching the power steering gear harness to the bracket.
49. Connect the engine harness electrical connector (1) to the CKP sensor harness.
50. Connect the engine harness electrical connector (2) to the power steering gear harness.




51. Connect the camshaft position sensor lead to the sensor.




52. Connect the following electrical connectors:

* TCM (1)
* ECM (2)
* A/C pressure sensor (3)

53. Install the air cleaner assembly. Refer to Air Cleaner Element Replacement (Service and Repair).




54. Connect the engine harness electrical connector to the EBCM.




55. Connect the engine harness electrical connector to the ABS module.




56. Install the engine harness connector to the bracket. Tighten the engine harness connector bolt (1).

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




57. Position the fuse block. Tighten the 4 integral bolts (2) attaching the fuse block.

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

58. Install the electrical center cover (1).




59. Connect the fuel feed line (1) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
60. Connect the EVAP line (2) to the purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




61. Remove the mechanic's wire holding the master cylinder. Position the master cylinder to the brake booster.
62. Install the master cylinder nuts.

Tighten the nuts to 33 N.m (24 lb ft).




63. Connect the brake pipe fittings (1, 2) to the ABS module.

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




64. Connect the from brake pipe fittings (1, 2) to the master cylinder.

Tighten the fittings to 30 N.m (22 lb ft).




65. Connect the brake fluid level switch electrical connector (3) to the master cylinder.
66. Connect the engine harness electrical connectors (1, 2) to the I/P harness electrical connectors.




67. Install the brake booster vacuum hose (1) to the intake manifold (2).
68. Install the brake booster vacuum hose to the brake booster (3).




69. Install the A/C compressor hose.
70. Install the A/C compressor hose nut at the A/C condenser.

Tighten the nut to 16 N.m (12 lb ft).




71. Install the A/C compressor hose.
72. Install the A/C compressor hose nut at the A/C receiver/dehydrator tube.

Tighten the nut to 16 N.m (12 lb ft).




73. Install the outlet hose to the radiator.
74. Connect the outlet hose clips to the fan shroud.
75. Using the J 38185 position the outlet hose clamp at the radiator.




76. Install the inlet hose to the radiator.
77. Using the J 38185 position the inlet hose clamp at the radiator.
78. Install the front tires and wheels. Refer to Tire and Wheel Removal and Installation (Service and Repair).
79. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (LS4) (Service and Repair).
80. Install the right fender diagonal brace. Refer to Front Fender Upper Diagonal Brace Replacement (Service and Repair).
81. Refill the engine with oil.
82. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging).
83. Refill the cooling system. Refer to Cooling System Draining and Filling (LS4 GE47716 Fill) (Service and Repair)Cooling System Draining and Filling (LS4 Static Fill) (Service and Repair).
84. Bleed the brake system. Refer to Hydraulic Brake System Bleeding (Manual) (Service and Repair)Hydraulic Brake System Bleeding (Pressure) (Service and Repair).
85. Check the transaxle fluid level, add fluid if necessary. Refer to Transmission Fluid Check (Testing and Inspection).
86. Install the engine sight shield. Refer to Upper Intake Manifold Sight Shield Replacement (Service and Repair).
87. Run the engine and inspect for leaks.