Engine - Installation

INSTALLATION

Special Tools:






CAUTION:
If the original engine has experienced a catastrophic failure or an individual failure with the piston, cylinder bore, engine block, valve or valve seat, the intake manifold MUST be replaced with a new manifold.

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





1. Install the Driver Side Engine Lifting Bracket (10242-1) (1) on the LH cylinder head with bolts (2) provided with the Engine Lifting Bracket. Tighten the bolts to 21 Nm (15 ft. lbs.).





2. Install the Passenger Side Engine Lifting Bracket (10242-2) (1) on the RH cylinder head with bolts (2) from the Engine Lifting Bracket. Tighten the bolts to 21 Nm (15 ft. lbs.).

3. Reposition the main wire harness to the rear of the engine compartment.

NOTE:
Right engine mount shown, left engine mount similar.





4. 2WD Vehicle, Position the engine mount (2) onto the engine support (1). Tighten the bolt (3) to 95 Nm (70 ft. lbs.).




5. If removed, install the engine mount brackets. Tighten the bolts (1) to 61 Nm (45 ft. lbs.).
6. Position the engine in the vehicle. Align the two outer engine mount bolts to the engine mount bracket (2).





7. Align the left and right engine mount isolators (6) within the frame mounting brackets and lower the engine so the weight is resting on the outer mounting bolts (4).

8. Install the inner engine mount to bracket through bolt (2).
9. Raise the vehicle.

10. Tighten the left and right engine mount nuts (3) to 61 Nm (45 ft. lbs.).

11. Install the engine mount heat shield (5). Tighten the nut to 12 Nm (106 in. lbs.).





12. Install the four upper transmission to engine bolts (1). Tighten the bolts to 55 Nm (41 ft. lbs.).







13. Install four transmission to the engine oil pan bolts (2 and 3) and tighten to 55 Nm (41 ft. lbs.).

14. Install two rubber plugs (1) covering the rear oil seal retainer flange bolts.





15. Install the side engine to transmission bolt (1). Tighten the bolt to 55 Nm (41 ft. lbs.).

16. Install the torque converter dust shield (3) with the bolt (2). Tighten the bolt to 12 Nm (106 in. lbs.).






17. Install the transmission cooler line retainer (1) to the oil pan flange.





18. If equipped with an automatic transmission, rotate the crankshaft in a clockwise direction and install the six torque converter bolts (1) through the starter mounting. Tighten the bolts to 42 Nm (31 ft. lbs.).





19. Connect the temperature sensor electrical connector (2).

20. Reposition the temperature sensor heat shield cover (1).





21. Install the battery ground (1) to the engine block. Tightened to 12 Nm (106 in. lbs.).





22. Install the battery positive cable (4) to the stop/start solenoid (1).

23. Connect the stop/start solenoid electrical connector (4).





24. Install the starter solenoid wiring harness (2) loom bolts (1). Tighten the bolts to 12 Nm (106 in. lbs.).





25. Install the starter (3) Service and Repair.





26. Connect the oil pump solenoid electrical connector (1).





27. Connect the crank shaft positioning sensor electrical connector (3).

28. Install the wiring harness retainers (2).

29. Install the transmission heater hose to the thermal management line.








30. Install the thermal management line bracket (1) to the transmission bell housing. Tighten the bolt (2) to 12 Nm (106 in. lbs.).





31. Position the catalytic converter to the cylinder heads.

32. Align the Y-pipe (1) to the catalytic converter flanges. Tighten the flange nuts to 23 Nm (17 ft. lbs.).

33. Partially lower the vehicle.





34. Align the heater line support braces to the right side cylinder head. Install the bolts (1) loose.

35. Install the oil indicator tube (2) into the oil pan. Align the mounting tab to the heater line brace bolt. Tighten the bolts to 12 Nm (106 in. lbs.).

NOTE:
Right catalytic converter shown, left catalytic converter similar.





36. Install the right and left catalytic converters upper bolts (2). Tighten the bolts to 37 Nm (27 ft. lbs.).





37. Connect the right and left upstream (1) and downstream (2) oxygen sensor connectors to the main wire harness.

38. Lower the vehicle.





39. Connect the power cord to the engine block heater (if equipped).

40. Lower the vehicle.





41. Install the A/C compressor (2) onto the engine. Tighten bolts to 28 Nm (21 ft. lbs.).

42. Connect the A/C compressor electrical connector (2).






43. Align the lower intermediate shaft coupler (1) to the steering gear (2). Tighten the bolt to 49 Nm (36 ft. lbs.).





44. Route the main wire harness on the left side of the engine.

45. Connect the left exhaust variable valve timing solenoid electrical connector (4).

46. Connect the left intake variable valve timing solenoid electrical connector (3).

47. Engage three wire harness retainers (1) to the left cylinder head cover.





48. Connect the left Camshaft Position (CMP) sensor (5).

49. Engage the main wire harness retainers (1 and 2) to the cylinder head cover mounting stud.





50. Route the main wire harness on the right side of the engine.

51. Connect the electrical connector (4) to the right Camshaft Position (CMP) sensor.

52. Connect three fuel injector electrical connectors (5).

53. Connect the main harness to the engine injection/ignition harness (1).

54. Engage three main wire harness retainers (3) to the right cylinder head cover.

55. Connect three ignition coil electrical connectors (2).





56. Install the B+ terminal to the generator stud (2). Tighten the nut (1) to 11 Nm (97 In. lbs.).

57. Connect the field circuit connector (3) to the generator.






58. Connect the right exhaust variable valve timing solenoid electrical connector (5).

59. Connect the right intake variable valve timing solenoid electrical connector (6).

60. Engage the wire harness retainers (1) to the cylinder head cover.






61. Secure the ground to the rear of the cylinder heads. Tighten the bolt (2) tightened to 12 Nm (106 in. lbs.).

62. Connect the electrical connector (3) to the ignition coil capacitors.





63. Install the accessory drive belt (1) Service and Repair.





64. Install the vacuum pump (4) Installation.





65. Connect the fuel supply hose (2) to the fuel pressure sensor.

66. Install the fuel pressure sensor electrical connector (3).






67. Install the insulator (2) to the two alignment posts (3) on top of the LH cylinder head cover.





68. Install the upper intake manifold and insulator Removal and Replacement





69. Connect the heater core return hose (1) to the water pump.

70. Install the lower radiator hose (2) to the engine coolant pump housing.





71. Install the heater supply hose to the coolant crossover (1).





72. Install the upper radiator hose (1) to the engine thermostat housing.





73. Install the A/C lines to the condenser (1). Tighten the nuts (2) to 23 Nm (17 ft. lbs.).

74. Recharge the A/C system Service and Repair.






75. Install the air cleaner lower housing assembly (4).





76. Position the air intake onto the throttle body. Hand tighten the clamp (1).

77. Install the IAT sensor electrical connector (2)





78. Install the breather tube (1) to the resonator (2).

79. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level Service and Repair

80. Fill the cooling system Service and Repair.

81. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.).

82. 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.