Engine - Installation

INSTALLATION - ENGINE ASSEMBLY





1. Position engine and transmission assembly under vehicle and slowly lower the vehicle over the engine/transaxle assembly.




NOTE: To prevent possible damage to engine mount bracket (3) or mount (2), the through bolt (1) must be started by hand to prevent cross threading.

2. Continue lowering vehicle until engine/transaxle aligns to mounting locations. Install mounting bolts at the right engine mount. Tighten bolts (1) to 118 Nm (87 ft. lbs.).




3. Install left transaxle mount (3). Tighten bolts (1) to 118 Nm (87 ft. lbs.).
4. Install upper engine torque strut.




5. Remove safety straps (4) from engine/transaxle assembly. Slowly raise vehicle enough to remove the engine dolly 6135 (7) and cradle 6710 (8).




6. Install power steering pump (1).
7. Connect power steering lines (2) to power steering pump (1).
8. Install A/C compressor.




9. Install lower engine torque strut (5)Torque Strut - Installation.
10. Automatic Transmission equipped vehicles:
a. Install torque converter bolts.
11. Manual Transmission equipped vehicles:
a. Install drive plate to clutch module bolts.




12. Install structural collar (4)Installation.




13. Turbocharger equipped vehicles: Install elbow (3), turbocharger support bracket (2), elbow support bracket (4), and upper and lower heat shields (1).




14. Non-Turbo equipped vehicles: Connect power steering pressure hose (3) to steering gear (1).




15. Turbocharger equipped vehicles: Connect both power steering hoses (5) to steering gear (1).




16. Connect exhaust system (2) to manifold.
17. Connect the downstream oxygen sensor.




18. Turbocharger equipped vehicles: Install charge air cooler to throttle body hose (1).
19. Install charge air cooler to turbocharger hose (3).
20. Install generator and mounting brackets.
21. Install accessory drive belts.




22. Install axle shafts Half Shaft - Installation.
23. Install right inner splash shield (3).
24. Install wheels and lower vehicle.
25. Install cooling module assembly (fan, radiator, A/C condenser, transmission oil cooler). Connect radiator fan electrical connector.
26. Turbocharger equipped vehicles: Connect power steering hoses to radiator.




27. Manual Transmission equipped vehicles:
a. Connect clutch hydraulic line (2).
b. Connect transmission shift linkage.
c. Connect transmission electrical connectors.

NOTE: It is not necessary to bleed the clutch hydraulic system. The quick-connect fittings close immediately after disconnection; allowing no fluid to escape.

28. Automatic Transmission equipped vehicles:
a. Connect transmission oil cooler lines using service splice kit. Refer to instructions provided with kit.
b. Connect transmission electrical connectors.
c. Connect transmission shift linkage.




29. Connect A/C lines (1) at junction near upper torque strut.
30. Connect upper A/C line to A/C condenser.
31. Install upper and lower radiator hoses.




32. Install upper radiator closure panel (1) and center brace (2)Installation.




33. Install grille (2) and tighten grill retaining fasteners (1)Grille - Installation.
34. Connect fuel line and heater hoses.
35. Connect coolant reserve/recovery hose to coolant outlet connector.
36. Connect brake booster vacuum hose to intake manifold.
37. Connect the proportional purge hose to throttle body.




38. Install all ground straps and connect engine wiring harness.
39. Position PDC (1) and install bolts Connect positive battery cable to PDC (1) and ground wire to vehicle body.
40. Connect engine wiring harness at Powertrain Control Module (PCM).
41. Connect throttle and speed control cables.
42. Install battery tray and battery Battery - Installation.
43. Connect cables to battery.




44. Install air cleaner housing assembly and connect clean air hose Air Cleaner Housing - Installation.
45. Install oil filter. Fill engine crankcase with proper oil to correct level.
46. Fill power steering system.
47. Fill cooling system.
48. Evacuate and recharge A/C system.
49. Start engine and run until operating temperature is reached. Check for leaks.
50. Perform torque strut adjustment procedure Adjustments.
51. Adjust transmission linkage, if necessary.