Engine - Installation
INSTALLATION
Special Tools:
NOTE: Do not use air tools to install Engine Lift Fixture and Adapter (2,3).
1. Install the engine lift fixture (2) and adapter (4).
2. Using a suitable engine hoist, lower the engine into in the engine compartment.
3. Align the engine with the transmission.
4. Install two transmission to engine block mounting bolts finger tight.
5. Lower the engine assembly until the engine mounts rest in the engine cradle crossmember.
NOTE: Left side shown, right side similar.
6. Align the engine mounts, install both left and right engine mount to frame retaining bolts (2) and tighten to 68 Nm (50 ft. lbs.).
7. Position both left and right engine mount heat shields (4), install the retaining nuts (3) and tighten to 27 Nm (20 ft. lbs.).
8. Remove the engine hoist and the jack supporting the transmission.
9. Raise and support the vehicle.
10. Install the transmission to oil pan bolts (1) and tighten to 54 Nm (40 ft. lbs.).
11. Install the remaining transmission bell housing to engine block bolts (2) and tighten to 68 Nm (50 ft. lbs.).
CAUTION: It is essential that the correct length bolts are used to attach the converter to the flexplate. Bolts that are too long will damage the clutch surface inside the torque converter.
12. Rotate the crankshaft in clockwise direction and install all torque converter to flexplate bolts (1) finger tight.
13. Verify that the torque converter is pulled flush to the flexplate and tighten bolts to 88 Nm (65 ft. lbs.).
14. Install the inspection cover (1) and tighten the retaining bolt (2) to 11 Nm (8 ft. lbs.).
NOTE: The Crankshaft Position (CKP) sensor is located at the right rear side of the engine block.
15. Connect the CKP sensor electrical connector (1).
16. Position the starter motor (1) into the transmission.
17. Install the three starter motor retaining bolts (2) and tighten to 54 Nm (40 ft. lbs.).
18. Connect the solenoid wire to the starter motor (snaps in place).
19. Position the battery cable to the solenoid stud, install the battery cable eyelet nut and tighten to 11 Nm (8 ft. lbs.).
20. Position the starter heat shield (4) and install the retaining nuts (3).
21. Position the catalytic converters (4) onto the exhaust manifold flanges, install the flange nuts (3) and tighten to 41 Nm (30 ft. lbs.).
22. Connect the oxygen sensor electrical connectors (2).
NOTE: Left side shown, right side similar.
23. Connect the right and left knock sensor (1) electrical connectors (5).
24. Install the heat shields onto both knock sensors (shield snaps on/off sensor).
25. Connect the transmission oil cooler lines to their retainers at the oil pan.
26. Install the lower radiator hose (1).
27. Lower the vehicle.
28. Remove the engine lift fixture (2) and adapter (4).
29. Position the left and right side wiring harness.
30. Lubricate the oil control valve (OCV) rubber O-ring seal with clean engine oil.
31. Install the OCV (3) and rotate into position.
32. Install the OCV retaining bolt (2) and tighten to 11 Nm (8 ft. lbs.).
33. Connect the OCV electrical connector (1).
34. Install the heater core tube (3) into the water pump.
35. Install the heater core tube retaining bolt (1) and tighten to 11 Nm (8 ft. lbs.).
36. Connect the electrical connector to the coolant temperature (ECT) sensor (2).
37. Connect the camshaft position sensor electrical connector (4).
NOTE: Install the intake manifold and throttle body as an assembly.
38. Install the intake manifold Intake Manifold - Installation.
39. Connect the heater hoses (1,2).
40. Connect the ground wires to the rear of each cylinder head.
NOTE: The ignition capacitor (2) is attached to the rear of the left cylinder head.
41. Connect the ignition capacitor (2) electrical connector (1).
42. Connect the oil pressure sensor electrical connector (1).
43. Connect the oil temperature sensor electrical connector.
44. Position the generator (2) and install two generator mounting bolts (1) finger tight.
45. Raise and support the vehicle.
46. Position the generator support bracket (3) to the engine mount, install the retaining nut (1) finger tight.
47. Position the generator support bracket (3) to the generator, install the retaining bolt (2) and tighten to 65 Nm (48 ft. lbs.).
48. Tighten the generator support bracket (3) to engine mount retaining nut (1) to 28 Nm (21 ft. lbs.).
49. Install the A/C compressor (3) A/C Compressor - Removal.
50. Position the belly pan and install the belly pan retainers (1).
51. Lower the vehicle.
52. Tighten two generator mounting bolts (1) to 65 Nm (48 ft. lbs.).
53. Snap the field wire connector into the rear of the generator.
54. Position the generator B+ terminal eyelet to the generator output stud, install the retaining nut and tighten to 13 Nm (10 ft. lbs.).
55. Snap the plastic insulator cap onto the B+ output terminal.
56. Position the front section of the A/C suction line (2) into the engine compartment.
57. Remove the tape or plugs from the fittings that connect the front section of the A/C suction line to the rear section of the A/C suction line (3).
NOTE: Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
58. Lubricate a new dual plane seal with clean refrigerant oil and install it onto the suction line fitting. Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
59. Connect the front section of the A/C suction line to the rear section of the A/C suction line.
60. Install the nut (1) that secures the front section of the A/C suction line to the rear section of the A/C suction line and tighten the nut to 22 Nm (16 ft. lbs.).
61. Position the front section of the A/C liquid line into the engine compartment.
62. Remove the tape or plugs from the fittings that connect the front section of the A/C liquid line to the rear section of the A/C liquid line (3).
NOTE: Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
63. Lubricate a new dual plane seal with clean refrigerant oil and install it onto the liquid line fitting. Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
64. Connect the front section of the A/C liquid line to the rear section of the A/C liquid line.
65. Install the nut (1) that secures the front section of the A/C liquid line to the rear section of the A/C liquid line and tighten the nut to 22 Nm (16 ft. lbs.).
66. Position the ignition coil electrical harness and connect all ignition coil electrical connectors (1).
67. Position the coolant bottle (1) and install the coolant bottle retaining bolts (2).
68. Install the Power Distribution Center (PDC) and mounting bracket.
69. Position the wire harness and secure to the right hand inner fender panel.
CAUTION: Do not let the tensioner arm snap back to the freearm position, sever damage may occur to the tensioner.
70. Rotate the accessory drive belt tensioner (8) clockwise until it contacts the stop and install the accessory drive belt (2) onto the pulleys, then slowly release the tensioner.
71. Install the cooling fan Cooling Fan - Installation.
72. Install the upper radiator hose (2).
73. Install the strut tower support (6) and tighten bolts to 38 Nm (28 ft. lbs.).
74. Install the cowl panel cover (1) Cowl Panel Cover - Installation.
75. Fill the crankcase with the specified type and amount of engine oil .
76. Fill the cooling system with the specified type and amount of engine coolant Service and Repair.
77. Position the engine cover (2) and secure the retaining grommets onto the ball studs.
78. Connect the negative battery cable and tighten nut (1) to 5 Nm (45 in. lbs.).
79. Perform the Refrigerant System Charge procedure Refrigerant System Charge.
80. Start the engine and check for leaks.