Installation
Installation Procedure1. Install the J39456 to the engine lift brackets and attach to the engine lift devise.
2. With the aid of an assistant complete the following:
1. Place the transmission into gear.
2. Position the transmission to the engine.
3. Rotate the output flange in order to align the transmission input shaft with the pressure plate.
4. Align the engine dowels (1) with the transmission.
3. Install the transmission mounting bolts (2-4).
^ Tighten the M12 transmission mounting bolts (2,3) to 75 Nm (55 ft. lbs.).
^ Tighten the M10 transmission mounting bolts (4) to 50 Nm (37 ft. lbs.).
4. Install the remaining transmission mounting bolts (1,2 and 4).
Tighten the M12 transmission mounting bolts to 75 Nm (55 ft. lbs.).
Important: Route the engine wiring harness as noted during removal.
5. Position the engine wiring harness to the engine.
6. Connect the engine wiring harness retaining clips (1) to the transmission mounting bolts.
7. Connect the engine wiring harness retainers.
8. Connect the engine wiring harness connectors to the electrical components.
9. Install the left engine mount bracket and retaining bolts.
Tighten the engine mount bracket bolts to 60 Nm (44 ft. lbs.).
10. Install the right engine mount bracket and retaining bolts.
Tighten the engine mount bracket bolts to 60 Nm (44 ft. lbs.).
11. Install the bolt securing the engine wiring harness retainer to the oil pan.
Tighten the engine wiring harness retainer to oil pan bolt to 50 Nm (37 ft. lbs.).
12. Install the 2 bolts (2-4) securing the engine wiring harness ground leads (1-3) to the left cylinder head.
^ Tighten the engine ground lead to left cylinder head bolt (2) to 30 Nm (22 ft. lbs.).
^ Tighten the coil ground to left cylinder head bolt (4) to 50 Nm (37 ft. lbs.).
Important: The following are on-vehicle procedures, use only the portion of the procedure needed for installation of the component.
13. Install the following components if previously removed:
^ Afterboil Coolant Pump Replacement in Engine Cooling
^ Battery Negative Cable Replacement (LHD) Battery Negative Cable Replacement (RHD) Battery Negative Cable Replacement (LY7) Battery Negative Cable Replacement (LS6) in Engine Electrical
^ Battery Positive Cable Replacement (LHD) Battery Positive Cable Replacement (RHD) Battery Positive Cable Replacement (LY7) Battery Positive Cable Replacement (LS6) in Engine Electrical
^ Coolant Heater Cord Replacement (LA3, LY9, K05) Coolant Heater Cord Replacement (LA3, LY9, KA3) Coolant Heater Cord Replacement (LY7 (KO5)) Coolant Heater Cord Replacement (LS6) in Engine Cooling
^ Coolant Pipe Replacement - Inlet (LA3, LY9) Coolant Pipe Replacement - Inlet (LY7) in Engine Cooling
^ Generator Replacement (LA3, LY9) Generator Replacement (LS6) Generator Replacement (LY7) in Engine Electrical
^ Starter Motor Replacement (LA3, LY9) Starter Motor Replacement (LY7) Starter Motor Replacement (LS6) in Engine Electrical
^ Surge Tank Hose/Pipe Replacement - Outlet (LHD, LY7) Surge Tank Hose/Pipe Replacement - Outlet (LHD) Surge Tank Hose/Pipe Replacement - Outlet (RHD) Surge Tank Hose/Pipe Replacement - Outlet (LS6) in Engine Cooling
^ Throttle Body Heater Hose/Pipe Replacement - Inlet (LA3, LY9) Throttle Body Heater Hose/Pipe Replacement - Inlet (LS6) in Engine Cooling
Important: Ensure clearance is maintained between the engine/transmission assembly and the following:
^ The A/C compressor
^ The A/C hoses
^ The brake pipes at the BPMV
^ The coolant bypass valve
^ The electric cooling fans
^ The engine wiring electrical harness
^ The fuel hoses
^ The power steering pump
^ The radiator
^ The remote power steering fluid reservoir
^ The vehicles tunnel
14. Alternate between the following in order to install the engine/transmission assembly into the engine compartment:
^ Carefully lower the engine/transmission assembly using the engine lift devise.
^ Position a lift jack under the rear of the transmission in order to aid in aligning the engine mount brackets with the engine mounts.
15. Remove the J39456 from the engine lift brackets.
Important: This will support the transmission while the vehicle is raised.
16. Install the transmission support to the vehicle.
17. Install the outer transmission support mounting bolts. Do not tighten.
18. Raise and support the vehicle.
19. Position a screw jack under the rear of the transmission.
20. Remove the outer transmission support mounting bolts.
21. Lower the screw jack only enough to install the shift control pins.
22. Connect the shift control rod (2) to the transmission and install the retaining pin (3).
23. Connect the shift reaction arm (4) to the transmission and install the retaining pin (5).
24. Install the shift control pin retaining clips (1).
25. Raise the screw jack fully into position.
26. Install the transmission support.
27. Remove the screw jack from under the vehicle.
28. Remove the mechanics wire securing the front propeller shaft to the shift reaction arm.
29. Install the propeller shaft coupler (1) to the transmission flange.
30. Install the clutch hydraulic hose retaining clip (1) to the clutch slave cylinder.
Important: Ensure the clutch hydraulic hose is routed in an upward direction above the clutch slave cylinder with no sharp bends, kinks, or downward loops, and does not come in contact with any sharp edges or potentially hot surfaces.
31. Install the clutch hydraulic hose to the vehicle.
32. Align the clutch hydraulic hose locating tab with the notch in the slave cylinder hose fitting.
33. Push the clutch hydraulic hose (2) into the clutch slave cylinder until a "click" is heard.
34. Tug gently on the clutch hydraulic hose (2) to ensure proper retention to the clutch slave cylinder.
35. Install the left engine mount upper retaining nut.
Tighten the engine mount nut to 80 Nm (59 ft. lbs.).
36. Install the right engine mount upper retaining nut.
Tighten the engine mount nut to 80 Nm (59 ft. lbs.).
37. Install the oil filter adapter.
38. Secure the ABS wiring harness retainers (2) to the engine frame.
39. If equipped, connect the variable effort steering electrical connector (1) to the power steering gear pigtail.
Important: Route the ABS wiring harness as noted during removal.
40. Secure the ABS wiring harness retainers to the following:
^ The lower control arms
^ The electric cooling fan
41. Connect the ABS wiring harness electrical connectors to the left and right wheel speed sensors.
42. Connect the EBCM electrical connector (1) to the EBCM (3).
43. Rotate the EBCM connector tab (2) down into the locked position.
44. Install the EBCM connector position assurance retainer (4) to the EBCM electrical connector (1).
45. If equipped, connect the electrical connector to the brake fluid pressure sensor.
46. Install the catalytic converter hanger bracket.
47. Install the left and right catalytic converters. and Catalytic Converter Replacement - Right (LA3, LY9) Catalytic Converter Replacement - Right (LY7) Catalytic Converter Replacement - Right (LS6) in Engine Exhaust.
48. Install the exhaust system.
49. Lower the vehicle.
50. Position the A/C compressor to the accessory mounting bracket.
51. Install the A/C compressor mounting bolts.
Tighten the A/C compressor mounting bolts to 20 Nm (15 ft. lbs.).
52. Connect the electrical connector to the A/C compressor.
53. Install the remote power steering fluid reservoir mounting bolts (1,3).
^ Tighten the remote power steering fluid reservoir to intake plenum mounting bolts (1) to 9 Nm (80 inch lbs.).
^ Tighten the remote power steering fluid reservoir to cylinder head mounting bolt (3) to 25 Nm (18 ft. lbs.).
54. Connect the following to the remote power steering fluid reservoir (1):
^ The vacuum brake booster hose
^ The wiring harness (2)
55. Connect the vacuum brake booster hose to the vacuum source.
56. Position the power steering pump to the accessory mounting bracket.
57. Install the power steering pump mounting bolts.
Tighten the power steering pump mounting bolts in sequence to 35 Nm (26 ft. lbs.).
58. Install the drive belt.
59. Install the power steering pressure hose retainer and nut to the A/C compressor stud.
Tighten the power steering hose retaining nut to 8 Nm (71 inch lbs.).
60. Connect the retainer (1) securing the engine wiring harness to the A/C pressure hose.
61. Install the power steering return hose retainer and nut to the A/C compressor stud.
Tighten the power steering hose retaining nut to 8 Nm (71 inch lbs.).
62. Connect the electrical connector (1) to the A/C refrigerant pressure switch (2).
63. Connect the 2 engine wiring harness connectors to the left body rail connectors.
64. Position the J38185 to the clamp in order to connect the surge tank outlet hose to the surge tank.
65. Position the J38185 to the clamp (1) in order to connect the inlet heater hose to the heater core.
66. Position the J38185 to the clamp (1) in order to connect the outlet heater hose to the afterboil coolant pump (2).
67. Insert the chassis hose/pipes into the retainer (4) located at the ECM bracket.
68. Close the retainer (4).
69. Connect the EVAP quick connect fitting (3).
70. Refer to Quick Connect Fitting(s) Service (Metal Collar) in order to connect the following quick connect fittings to the fuel rail:
^ The feed hose/pipe (2)
^ The return hose/pipe (1)
71. Position the J38185 to the clamp (1) in order to connect the coolant bypass inlet hose to the afterboil coolant pump pipe.
72. Position the J38185 to the clamp (2) in order to connect the coolant bypass outlet hose to the coolant inlet pipe.
73. Position the J38185 to the clamps in order to connect the surge tank inlet hose to the following:
^ The radiator
^ The throttle body assembly
74. Install the outlet radiator hose.
75. Install the inlet radiator hose.
76. Fill the cooling system.
77. Connect the engine wiring harness connector (1) to the coolant bypass solenoid.
78. Install the bolt securing the engine wiring harness ground lead to the right body rail.
Tighten the engine wiring harness ground lead bolt to 9 Nm (80 inch lbs.).
79. Connect the engine wiring harness connector at the right shock tower.
80. Install the intake air resonator.
81. Install the air cleaner assembly.
82. Install the nut (1) securing the battery positive cable (2) to the underhood fuse block.
Tighten the battery positive cable to underhood fuse block nut to 15 Nm (11 ft. lbs.).
83. Connect the battery positive cable to the battery.
Tighten the battery cable to 17 Nm (13 ft. lbs.).
84. Connect the engine wiring harness electrical connector to the underhood fuse block.
85. Install the underhood fuse block cover to the underhood fuse block.
86. Install the bolt (1) securing the battery negative cable to the side rail.
Tighten the battery negative cable to side rail bolt to 36 Nm (27 ft. lbs.).
87. Connect the body harness connector (3) to the battery negative cable.
88. Connect the battery negative cable.
89. Position the front air inlet panel to the battery tray and cowl.
90. Install the fasteners securing the front air inlet panel to the battery tray and cowl.
Tighten the front air inlet panel assembly fasteners to 6 Nm (53 inch lbs.).
91. Install the wiper motor module.
92. Install the hood.
93. Fill the engine oil.
Engine Final Test and Inspection
Complete the following procedure after the engine is installed in the vehicle:
1. With the ignition OFF or disconnected, crank the engine several times. Listen for any unusual noises or evidence that any parts are binding.
2. Start the engine and listen for abnormal conditions.
3. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
4. Run the engine at approximately 1000 RPM until the engine reaches normal operating temperature.
5. While the engine continues to idle raise and support the vehicle.
6. Inspect for oil, coolant and exhaust leaks while the engine is idling.
7. Lower the vehicle.
8. Perform the idle learn procedure. Refer to Idle Learn Procedure in Engine Controls-2.6L and 3.2L.
9. Perform a final inspection for the proper engine oil and coolant levels.
10. Road test the vehicle.