Engine - Installation

INSTALLATION

Special Tools:















NOTE: If installing a replacement engine, transfer components such as engine mount brackets, block heater, accessories, heater hoses and tubes to the replacement engine.

1. If required, remove the upper intake manifold Intake Manifold - Removal.





2. Install the Driver Side Engine Lifting Bracket (1) on the LH cylinder head with bolts (2) provided with the Engine Lifting Bracket. Tighten the bolts to 21 Nm (15 ft. lbs.).





3. Install the Passenger Side Engine Lifting Bracket (1) on the RH cylinder head with bolts (2) from the Engine Lifting Bracket. Tighten the bolts to 21 Nm (15 ft. lbs.).





4. Position a load-leveling lifting sling (2), such as OTC(R) 4305 Engine Load Leveler or equivalent, between the engine lifting brackets (3) and an engine hoist (1).





5. Install the transaxle (2) to the engine (1) if required. Secure with six transaxle upper bellhousing-to-block bolts (3) tightened to 70 Nm (52 ft. lbs.).





6. Position the engine/transaxle assembly on the Power Train Dolly (3) and Engine Support Cradle (2).
7. Loosen the cradle engine mounts to allow movement for positioning onto the engine locating holes on the engine block and oil pan rail. Place Adapter (1) on the front post and align to the oil pan mounting stud. Tighten the post mounts to the cradle frame. Secure the engine/transaxle assembly to the dolly/cradle with safety straps (4). Remove the engine lifting brackets.
8. If required, install the following components for installation on the replacement engine:
- Accessory drive belt tensioner
- Upper intake manifold support bracket
- Block heater (if equipped)





9. Position the engine/transaxle assembly under the vehicle. Slowly lower the vehicle in short length spans. Inspect at each interval for potential engine or transaxle contact to vehicle components. Move the cradle/dolly fixture as necessary to allow for clearance.
10. Install three bolts (1) to the RH engine mount bracket (2) and tighten bolts (1) to 55 Nm (41 ft. lbs.).





11. Install two bolts (1) to the LH engine (transmission) mount bracket (2).
12. Position the main wire harness onto the engine.





13. Engage the wire harness retainer (1) to the gearshift cable bracket (4).
14. Connect two output shaft speed sensors connectors (2 and 3).
15. Connect the gearshift cable (5) from the bracket (4).





16. Connect the gearshift cable (1) from transaxle manual valve lever (2).





17. Connect the oil cooler lines (2) to transaxle.
18. Connect the transmission input shaft speed sensor connector (1).





19. Engage the main wire harness retainer (1) to the valve body pan.
20. Connect transmission solenoid harness connector (2).





21. Raise and support the vehicle Maintenance.
22. If required, install the four transaxle-to-engine lower bolts (2) and tighten to 70 Nm 52 ft. lbs.).
23. If required, install the torque converter-to-driveplate bolts (1) and tighten to 88 Nm (65 ft. lbs.).





24. If required, install the transaxle torque converter housing dust cover (1) and rubber plugs (2).





25. Install the rear engine mount bracket (1) with four bolts (2). Tighten bolts (2) to 110 Nm (81 ft. lbs.)
26. Install the bolt (3) to the rear engine mount isolator and tighten to 60 Nm (44 ft. lbs.).





27. Lower the vehicle.
28. If required, install the heater core supply tube (1) with two bolts (2) and tighten to 12 Nm (106 in. lbs.).





29. Install the LH upper intake manifold support brackets (1). Loosely install the studbolts (2).





30. Engage three main wire harness retainers (1) to the right cylinder head cover.





31. Raise and support the vehicle Maintenance.
32. Connect the oil pump solenoid electrical connector (2).
33. Engage the wire harness retainer (1) to the engine block.





34. Install the power steering pump and bracket as an assembly with three bolts (1) and tighten to 25 Nm (18 ft. lbs.).
35. Engage the wire harness retainer (2) to the power steering pump.





36. Install the power steering pump heat shield (1) Tighten bolts (2) to 25 Nm (18 ft. lbs.).





37. Connect the power cord to the engine block heater (if equipped).
38. Engage the downstream oxygen sensor connector (4) to the engine mount.
39. Engage one wire harness retainer (2) to the engine block and one wire harness retainer (1) to the transmission mounting stud.
40. Connect the Crankshaft Position (CKP) sensor electrical connector (3).





41. Position the heat-shield (1) over the Crankshaft Position (CKP) sensor.





42. Install the rear engine mount heat shield (2). Tighten bolts (1) to 14 Nm (124 in. lbs.).





43. Install the A/C compressor (1) A/C Compressor - Installation.





44. Install the lower radiator hose (1).





45. Install the starter Starter - Installation.





46. Install the front engine mount bracket (1). Tighten bolts (2) to 55 Nm (41 ft. lbs.).





47. Install both catalytic converters (3) and connect the oxygen sensor connectors to the main wire harness Catalytic Converter - Installation.
48. Install the crossunder pipe (2) .
49. Install the front fore and aft crossmember (1) Crossmember - Installation.





50. Install the intermediate shaft and both axle shafts (2) Half Shaft - Installation.





51. Install the right splash shield (2).





52. Install left lower splash shield (2).





53. Install both front tire and wheel assemblies (1) Tires And Wheels - Installation.





54. Install the belly pan.
55. Lower the vehicle.





56. Engage the wire harness retainer (2) to the upper intake manifold support bracket mounting stud.
57. Engage the wire harness retainer (3) to the intake manifold support bracket.
58. Connect the electrical connector (1) to the right Camshaft Position (CMP) sensor.





59. Connect the following hoses to the upper intake manifold:
- Positive Crankcase Ventilation (PCV) (3)
- Vapor purge (6)
- Brake booster (2).

60. Engage the ETC harness to the clip (8) on the throttle body. Engage the wire harness retainers (4 and 5) to the upper intake manifold near the MAP sensor and reposition the wire harness.
61. Connect the electrical connectors to the Manifold Absolute Pressure (MAP) sensor (1) and the Electronic Throttle Control (ETC) (7).




62. Engage two wire harness retainers (1) to the right cylinder head cover.
63. Connect the electrical connectors (2) to the variable valve timing solenoids on the right cylinder head.





64. Connect the main harness to the engine oil pressure/temperature harness (2) at the rear of the left cylinder head.
65. Connect the main harness to the engine injection/ignition harness (1) at the rear of the left cylinder head.





66. Engage the main wire harness retainer (1) to the rear of the lower intake manifold.
67. Engage one main wire harness retainer (2) to the cylinder head cover and one main wire harness retainer (4) to the cylinder head cover mounting stud.
68. Connect the left Camshaft Position (CMP) sensor (5).
69. Connect the Engine Coolant Temperature (ECT) sensor connector (3).





70. Engage two lower wire harness retainers (3) to the intake manifold support brackets.
71. Engage two upper wire harness retainers (2) to the intake manifold support brackets.





72. Engage three wire harness retainers (1) to the left cylinder head cover.
73. Connect the electrical connectors (2) to the variable valve timing solenoids on the left cylinder head cover.





74. Connect the electrical connector (2) to the A/C pressure transducer.
75. Engage the fuel purge solenoid wire harness retainer (1) to the engine cowl.
76. Connect the electrical connector (3) to the fuel purge solenoid.





77. Install the generator (2) Generator - Installation.





78. Install the accessory drive belt (7) Serpentine Accessory Drive Belt - Installation.





79. Connect the heater core return hose (1).





80. Connect the heater core supply hose (1) Service and Repair.





81. Install the cooling fan module (1) Cooling Fan - Installation.





82. Install the upper intake manifold (2) Intake Manifold - Installation.





83. Install the heater core return tube (1) with the nut (2) and bolt (3).





84. Install the upper radiator hose (2) and engage the hose retainer (1) to the intake manifold.





85. Install the coolant recovery bottle (1) Coolant Recovery Bottle - Installation.





86. Disconnect the fuel line (1) from the fuel rail inlet.





87. Install the resonator (1) Installation.





88. Install the air cleaner body (1) Air Cleaner Body - Installation.





89. Install the electric vacuum pump and mounting bracket (1) Installation.





90. Fill engine crankcase with proper oil to correct level.
91. Evacuate and recharge Air Conditioning system Refrigerant System Charge.
92. Fill cooling system Service and Repair.
93. Install the engine cover (1).
94. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.).
95. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level Service and Repair

NOTE: The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components.