Installation

Engine Replacement

Special Tools
* J 37096 Flywheel Holder
* J 25033-C Pulley Installer
* J 25034-C Pulley Remover

Installation Procedure




1. Install a engine lifting device to the engine.
2. Remove the engine from the engine stand.
3. Position the flexplate to the crankshaft.
4. Install the flywheel bolts finger tight.
5. Install the J 37096 to the flexplate in order to prevent the flexplate from rotating.

Caution: Refer to Fastener Caution Fastener Caution.

6. Tighten the flexplate bolts to 70 Nm (52 lb ft).




7. Remove the J 37096 .




8. Install the engine to the vehicle and install the engine to the transaxle.
9. Install the transaxle-to-engine bolts/studs and tighten to 75 Nm (55 lb ft).




10. Install the radiator inlet hose to the engine.
11. Position the radiator inlet hose clamp at the engine.




12. Connect the EVAP purge line quick connect fitting (2) to the canister purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service Plastic Collar Quick Connect Fitting Service.
13. Connect the fuel feed line quick connect fitting (3) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service Metal Collar Quick Connect Fitting Service.
14. Engage the fuel/EVAP line clip (1) to the MAP sensor bracket.




15. Install the heater outlet and inlet hoses to the engine.
16. Position the heater inlet(1) and outlet (2) hose clamps at the engine.




17. Install the brake booster vacuum hose (1) to the intake manifold.
18. Position the brake booster vacuum hose clamp (2) at the intake manifold.




19. Install the radiator surge tank hose to the surge tank pipe.
20. Position the radiator surge tank hose clamp (1) at the surge tank pipe.
21. Remove the support from the transaxle and raise the vehicle.




22. Install the radiator outlet hose to the thermostat housing.
23. Position the radiator outlet hose clamp at the thermostat housing.




24. Install the transaxle brace and bolts and tighten the bolts to 50 Nm (37 lb ft).




25. Position and install the A/C compressor onto the stud.
26. Tighten the A/C compressor nut first, then the rear bolt, then the front bolt to 50 Nm (37 lb ft).




27. Install the flexplate to torque converter bolts and tighten to 62 Nm (46 lb ft.




28. Install the torque converter cover and bolts and tighten to 10 Nm (89 lb in).
29. Install the catalytic converter. Refer to Catalytic Converter Replacement - Left Side (LZ4) Catalytic Converter Replacement - Left SideCatalytic Converter Replacement - Left Side (LY7) Catalytic Converter Replacement - Left Side and/or Catalytic Converter Replacement - Right Side (LZ4) Catalytic Converter Replacement - Right SideCatalytic Converter Replacement - Right Side (LY7) Catalytic Converter Replacement - Right Side.
30. Install the engine mount. Refer to Engine Mount Replacement Engine Mount Replacement.




31. Position the branches of the engine wiring harness over the engine.
32. Install the battery cable ground terminal (1) and the engine wiring harness ground terminal (2) to the transaxle stud.
33. Install the engine wiring harness ground nut (3) and tighten to 25 Nm (18 lb ft.




34. Install the engine wiring harness clip (6) to the transaxle stud.
35. Install the engine wiring harness clip nut (5) and tighten to 25 Nm (18 lb ft).
36. Install the engine wiring harness clip bolt (4) and tighten to 25 Nm (18 lb ft).




37. Connect the engine wiring harness electrical connector (1) to the transaxle.




38. Connect the engine wiring harness electrical connector (1) to the neutral safety backup switch.




39. Install the engine wiring harness clip to the vehicle speed sensor bracket.




40. Connect the engine wiring harness electrical connector to the vehicle speed sensor.




41. Connect the engine wiring harness electrical connector to the TCM.




42. Connect the engine wiring harness electrical connector (1) to the PCM.




43. Connect the body harness electrical connector to the PCM.




44. Connect the engine wiring harness electrical connector (3) to the body wiring harness electrical connector (2).




45. Connect the engine wiring harness electrical connector (1) to the body wiring harness electrical connector (2).




46. Install the engine wiring harness clip (3) to the engine.
47. Connect the engine wiring harness electrical connector (2) to the camshaft phasor.
48. Install the engine wiring harness bolt (1) and tighten to 10 Nm (89 lb in).




49. Connect the engine wiring harness electrical connector (2) to the fuel injector inline electrical connector.




50. Connect the engine wiring harness electrical connector (3) to the generator.
51. Install the engine wiring harness terminal (2) to the generator.
52. Install the engine wiring harness to generator stud nut (1) and tighten to 20 Nm (15 lb ft).
53. Position the engine wiring harness terminal boot (4).




54. Install the engine wiring harness clips (1, 2) to the ignition control module bracket.




55. Connect the engine wiring harness electrical connector (2) to the rear upper HO2S.
56. Install the CPA retainer (3).




57. Connect the engine wiring harness electrical connector (2) to the ignition control module.
58. Connect the engine wiring harness electrical connector (1) to the MAP sensor.




59. Connect the engine wiring harness clip (3) to the engine lift bracket.
60. Connect the engine wiring harness clips (1, 2) to the heater inlet and outlet pipe brackets.




61. Connect the engine wiring harness electrical connector (4) to the HO2S.
62. Install the CPA retainer (5).
63. Connect the engine wiring harness electrical connector (2) to the ETC.
64. Connect the engine wiring harness electrical connector (1) to the EVAP canister purge solenoid.




65. Unsecure and position the power steering pump.
66. Install the power steering line clip (2) to the stud.
67. Install the power steering line clip nut (1) to the generator stud and tighten the nut to 5 Nm (44 lb in).
68. Install the power steering pump bolts (3) and tighten to 25 Nm (18 lb ft).




69. Using the J 25033-C , install the power steering pump pulley (1).




70. Connect the engine wiring harness electrical connector (2) to the CKP sensor.
71. Connect the engine wiring harness electrical connector (1) to the knock sensor.




72. Install the engine wiring harness electrical connector (2) rosebud to the transaxle mount.
73. Connect the lower rear HO2S electrical connector to the engine wiring harness electrical connector (2).
74. Install the lower rear CPA retainer (1).




75. Install the engine wiring harness electrical connector clip (2) to the thermostat housing stud.
76. Connect the lower front HO2S electrical connector to the engine wiring harness electrical connector (1).
77. Install the CPA retainer (3).




78. Connect the engine wiring harness electrical connector to the A/C compressor.




79. Install the engine wiring harness clip (2) to the engine boss.
80. Install the engine wiring harness clip bolt (3) and tighten to 25 Nm (18 lb ft).
81. Install the engine wiring harness clip (1) to the A/C compressor bracket.




82. Install the engine wiring harness ground terminal (2) to the engine boss.
83. Install the engine wiring harness ground bolt (1) and tighten to 25 Nm (18 lb ft).




84. Connect the engine wiring harness electrical connector (2) to the knock sensor.
85. Connect the engine wiring harness electrical connector (1) to the oil pressure sensor.




86. Install the oil pressure sensor heat shield and nuts and tighten to 10 Nm (89 lb in).
87. Install the starter motor. Refer to Starter Replacement (LAT) Service and RepairStarter Replacement (LE5/LE9) Service and RepairStarter Replacement (LZ4 or LZE) Starter Replacement (LZ4 or LZE)Starter Replacement (LY7) Starter Replacement (LY7).
88. Install the drive belt and the engine mount snubber. Refer to Drive Belt Replacement Service and Repair.
89. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement Intake Manifold Cover Replacement.
90. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement Service and Repair.
91. Install the hood. Refer to Hood Replacement.
92. Fill the cooling system. Refer to Cooling System Draining and Filling (Static Fill-LY7, LZE, LZ4) Cooling System Draining and FillingCooling System Draining and Filling (GE 47716) Cooling System Draining and Filling (GE 47716).
93. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (LAT) Service and RepairBattery Negative Cable Disconnection and Connection (LE5, LE9, LZ4, LZE, or LY7) Service and Repair.
94. Prelube the engine. Refer to Engine Prelubing 103. Engine Prelubing.
95. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn Testing and Inspection.
Note: After an overhaul the engine should be tested. Use the following procedure after the engine is installed in the vehicle.

1. Disable the ignition system.
2. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
3. Enable the ignition system.
4. Start the engine and listen for unusual noises.
5. Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
6. Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.
7. Listen for sticking lifters or other unusual noises.
8. Inspect for fuel, oil, and/or coolant leaks while the engine is running.
9. Perform a final inspection for the proper oil and coolant levels.

96. Close the hood.