With Automatic Transmission

WITH AUTOMATIC TRANSMISSION

Special Tools:

NOTE: Perform the following steps to prepare a replacement engine for installation into the vehicle.

1. Install the RH engine mount bracket (1) with six bolts (2) tightened to 25 Nm (18 ft. lbs.).

2. Install the RH engine mount isolator (3) and support bracket (1) to the engine mount bracket with three bolts. Tighten the isolator to engine bracket bolts in the sequence shown to 60 Nm (44 ft. lbs.).

4. Install the (10299) (1) on the vacuum pump mounting surface with three bolts (2) provided with the engine lifting bracket. Tighten the bolts to 20 Nm (15 ft. lbs.).

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

NOTE: Perform the following steps to install components on a replacement engine if required.

6. Install the accessory mounting bracket (1) with three bolts (4) and two nuts (2 and 3) tightened as follows:
- Three bolts (4) to 50 Nm (37 ft. lbs.)
- One nut (3) to 50 Nm (37 ft. lbs.)
- One nut (2) to 25 Nm (18 ft. lbs.)

7. Install the ground wire with the bolt (5) tightened to 9 Nm (80 in. lbs.).

8. Install the block heater (3) (if equipped) Engine Block Heater - Installation.

9. Install the oil level indicator tube (1). Tighten the bolt (2) to 9 Nm (80 in. lbs.).

10. Install the A/C compressor (3) with discharge line (1) and suction line (5) A/C Compressor - Installation.

11. Install the generator (3) and connect the electrical wiring Generator - Installation.

12. Install the accessory drive belt (4) Serpentine Accessory Drive Belt - Installation.

13. Install the transmission adapter plate (1) with three bolts (3 and 4) and one bolt and nut (2) as follows:
- One bolt (4) to 60 Nm (44 ft. lbs.)
- One bolt and nut (2) to 60 Nm (44 ft. lbs.)
- Two bolts (3) to 40 Nm (30 ft. lbs.)

14. Install the flexplate (1) Flexplate - Installation

15. Install the starter assembly (5) and connect the electrical wiring (2) Starter - Installation.

NOTE: Perform the following steps to install the transmission to the engine if required.

16. Install the transmission on the engine with two upper mounting bolts (1) tightened to 60 Nm (44 ft. lbs.).

17. Install the four lower transmission mounting bolts (1) and the oxygen sensor harness bracket (2). Tighten bolts (1) to 40 Nm (30 ft. lbs.).

18. Install the six torque converter bolts (1). Tighten the six bolts in two steps as follows:
- Step 1: All to 20 Nm (15 ft. lbs.).
- Step 2: All to 60 Nm (44 ft. lbs.).

19. Install the torque converter access cover (1).

20. Position the engine and transmission in the vehicle.

21. Install the LH engine mount isolator (1) with three bolts (2 and 3). First tighten the isolator to engine bracket bolt (3) to 110 Nm (81 ft. lbs.) and then tighten the isolator to body bolts (2) to 50 Nm (37 ft. lbs.).

22. Install the RH engine mount isolator (3) and support bracket (1) to the engine mount bracket with three bolts. Tighten the isolator to engine bracket bolts in the sequence shown to 60 Nm (44 ft. lbs.).
23. Install the RH engine mount isolator (3) to the body with three bolts (2). Tighten the isolator to body bolts (2) to 60 Nm (44 ft. lbs.).

CAUTION: When servicing components near the vacuum pump, avoid contact with the plastic nipple that connects the vacuum pump to the brake booster hose. It is possible to crack the plastic nipple resulting in a brake booster vacuum leak.

CAUTION: The vacuum hose and the pressurized coolant bottle return hose have the same quick-connect fitting end. Verify that the hoses are correctly installed. Failure to properly install the hoses can result in engine damage.

24. Install the vacuum pump (1) and wiring harness bracket Vacuum Pump - Installation.
25. Connect the main wire harness connector (2) to the engine harness.

26. Connect the fuel vapor purge hose (3) to the intake manifold.
27. Connect the fuel line (2) to the fuel rail and close the hose retainer (1)Service and Repair.

28. Install the A/C suction line (1) with a new O-ring seal to the A/C expansion valve. Install the nut (2) and tighten to 20 Nm (15 ft. lbs.).
29. Connect the heater core inlet hose (4) and outlet hose (3) to the heater core.

30. Install the battery cable (1) to the battery terminal and tighten the nut (2) to 5 Nm (45 in. lbs.).

31. Install the ground strap to the transmission and tighten the bolt (3) to 9 Nm (80 in. lbs.).
32. Install the gearshift cable (2) to the bracket (1).
33. Connect the gearshift cable (2) to the transmission manual valve lever (4).
34. Connect the wire harness connector (5) to the transmission range selector switch.

35. Install the upper radiator hose (2) to the engine.
36. Install the lower radiator hose (3) to the engine.
37. Install the windshield washer fluid reservoir and engage the hose retainer (4) to the filler neck.

38. Install the pressurized coolant bottle (5) Coolant Recovery Bottle - Installation.

39. Raise and support the vehicle Maintenance.
40. Install the rear engine mount isolator (5) in the bracket (3) with two bolts (4) tighten to 60 Nm (44 ft. lbs.). Install the isolator bolt (1) and tighten to 130 Nm (96 ft. lbs.).

41. Install both axle shafts Half Shaft - Removal.

42. Lower the vehicle.
43. Install the maniverter (4), cooling module, front fascia, inner wheel well splash shields, wheels and tires Exhaust Manifold - Installation.

44. Install the belly pan Belly Pan - Installation.

45. Lower the vehicle.
46. Position the battery tray and PCM in the vehicle. Route the wire harness and close the wire harness retainers (3).
47. Install the ground strap (4) with nut (1) tightened to 5 Nm (44 in. lbs.).

48. Install the battery tray (3) with one nut (5) and two bolts (1) tightened to 25 Nm (18 ft. lbs.).
49. Engage the engine wire harness connector (2) to the battery tray (3).
50. Engage two engine wire harness retainers (4) to the battery tray (3).
51. Engage two starter wire harness retainers (6) to the battery tray (3).

52. Connect the Powertrain Control Module (PCM) electrical connectors (1 and 2).

53. Install the oil separator housing (4) to the cylinder head cover with three bolts (2) tightened to 13 Nm (115 in. lbs.).
54. Connect the vent hose (3) to the oil filler neck.
55. Connect the PCV hose (1) to the intake manifold.

56. Install the air cleaner body (6) Air Cleaner Body - Installation.

57. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level Service and Repair.
58. Fill the cooling system Service and Repair.
59. Install and connect the battery Battery - Installation.
60. Evacuate and charge the refrigerant system Refrigerant System Charge.
61. Install the engine cover (1).
62. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level Service and Repair.
63. Check the transmission for correct fluid level Procedures.

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 PCM/ECM Reprogramming .