Operation CHARM: Car repair manuals for everyone.

Part 4



Engine Replacement

Tools Required
* J 37097-A Hose Clamp Remover/Installer
* J 38185 Hose Clamp Pliers
* J 39580 Universal Engine Support Table
* J 41623-B Cooler Quick Connect Tool
* J 42640 Steering Column Lock Pin

Installation Procedure - Part 4

151. Install the nut (1) securing the starter cable to the BEC.

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




152. Install the junction block cover.
153. Install the air cleaner. Refer to Air Cleaner Assembly Replacement (Service and Repair).
154. Install the front compartment sight shield. Refer to Front Compartment Sight Shields Replacement (Front Compartment Sight Shields Replacement).




155. Connect the fuel feed and EVAP line quick-connect fittings (1, 2). Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service) andPlastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




156. Connect the brake booster vacuum hose to the vacuum connection.
157. Position the brake booster vacuum hose clamp at the engine port.
158. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair).
159. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement (Service and Repair).
160. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill) (Service and Repair)Cooling System Draining and Filling (Vac-N-Fill) (Service and Repair).
161. Bleed the brake system. Refer to Hydraulic Brake System Bleeding (Manual) (Service and Repair)Hydraulic Brake System Bleeding (Pressure) (Service and Repair).
162. Recharge the A/C refrigerant system. Refer to Refrigerant Recovery and Recharging (Non HP2) (Refrigerant Recovery and Recharging (Non HP2)).
163. Bleed the power steering system. Refer to Power Steering System Bleeding (Service and Repair).
164. Check the wheel alignment. Refer to Wheel Alignment Measurement (Service and Repair).
165. Pre-lube the engine. Refer to Engine Prelubing (Overhaul).
166. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (Service and Repair).
167. With the ignition OFF or disconnected, crank the engine several times. Listen for any unusual noises or evidence that any parts are binding.
168. Start the engine and listen for abnormal conditions.
169. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
170. Run the engine at approximately 1000 RPM until the engine reaches normal operating temperature.
171. While the engine continues to idle raise and support the vehicle.
172. Inspect for oil, coolant and exhaust leaks while the engine is idling.
173. Lower the vehicle.
174. Perform the crankshaft position (CKP) system variation learn procedure. Refer to Crankshaft Position System Variation Learn (Programming and Relearning).
175. Perform a final inspection for the proper engine oil and coolant levels.
176. Road test the vehicle.