Engine - Installation

INSTALLATION - ENGINE ASSEMBLY

1. Position engine and transmission assembly under vehicle. Slowly lower the vehicle down over the engine and transmission. It is necessary to move the engine/transmission assembly with the dolly for clearance around body flanges.
2. Align engine and transmission mounts to attaching points. Install mounting bolts at the right engine mount (Figure 1) and left transmission mount (Figure 2).




Figure 1 Right Mount to Engine










Figure 2 LEFT MOUNT TO FRAME BRACKET






3. Remove the safety straps from around engine.
4. Slowly raise vehicle enough to remove the engine dolly and cradle Special Tools 6135, 6710, 6848 and 6909.
5. Remove Special Tools 6912 and 8444.
6. Lower the vehicle.
7. Install power steering pump and pressure line support.
8. Install the generator and wiring harness.
9. Raise vehicle.
10. Attach wiring harness support clip to the engine oil dipstick tube.
11. Connect oil pressure switch electrical connector.
12. Install the A/C compressor.
13. Install the water pump pulley.
14. Connect the radiator lower hose.
15. Install the accessory drive belt and splash shield.
16. Connect the engine block heater electrical connector (if equipped).
17. Connect the knock sensor electrical connector (3.8L only).
18. Install the torque converter to flex plate bolts.
19. Install the transaxle case cover.
20. Install the powertrain struts.
21. Install the engine rear mount bracket.
22. Install the engine front mount and bracket assembly.
23. AWD equipped; Install the power transfer unit (PTU).
24. Install the axle shafts.
25. Connect exhaust pipe to manifold.
26. Install crossmember cradle plate.
27. Lower vehicle.
28. Connect transaxle shift linkage.
29. Connect transaxle electrical connectors.
30. Remove plugs from transmission cooler hoses and install transaxle oil cooler line service splice kit. Refer to instructions included with kit.
31. Install transaxle dipstick tube and attach electrical harness clip.
32. Connect the A/C lines to compressor.
33. Connect the A/C compressor electrical connector.
34. Evacuate and recharge A/C system.
35. Connect crankshaft and camshaft position sensors.
36. Connect the fuel injector electrical harness connector and engage clip to support bracket.
37. Connect engine coolant temperature (ECT) sensor and ignition coil electrical connectors.
38. Connect the ground strap to rear of cylinder head.
39. Install power steering reservoir.
40. Engage wire harness clip to engine right side mount.
41. Connect the brake booster and speed control vacuum hoses.
42. Connect the vacuum hoses to the throttle body.
43. Connect the EGR transducer electrical connector (if equipped).
44. Connect the TPS, IAC, and MAP sensor electrical connectors.
45. Connect throttle cables to throttle body.
46. Install the radiator fans.
47. Connect the radiator upper hose.
48. Connect the heater hoses. Remove pinch-off pliers from the rear heater hoses (if equipped).
49. Install the radiator upper support crossmember.
50. Install the wiper module.
51. Connect the fuel line to fuel rail.
52. Install the air cleaner and hoses.
53. Install new oil filter. Fill engine crankcase with proper oil to correct level.
54. Connect negative cable to battery.
55. Fill the cooling system.
56. Start engine and run until operating temperature is reached.
57. Adjust transmission linkage, if necessary.