Installation

Engine





Special Tool(s)





Material

All vehicles

1. Using a suitable floor crane, position the engine assembly into the vehicle.





2. CAUTION: Only use hand tools when installing the LH engine mount bolt or damage to the engine mount can occur.

NOTE: Early build vehicles are equipped with an M14 through bolt. Late build vehicles are equipped with an M18 through bolt.

Apply high strength threadlocker to the bolt threads and install the LH engine support insulator bolt.

1. If the M14 through bolt engine support insulator nut is missing or damaged, install a new nut using service part number W709375.
2. If the M14 through bolt engine support insulator nut cage is damaged or missing, install a new nut using service part number W520516-S301.
- Early build vehicles, tighten to 220 Nm (162 ft. lbs.).
- Late build vehicles, tighten to 350 Nm (258 ft. lbs.).





3. CAUTION: Only use hand tools when installing the RH engine mount nuts or damage to the engine mount can occur.

Apply high strength threadlocker to the stud threads and install the RH engine support insulator washer and nuts.
- Tighten to 250 Nm (184 ft. lbs.).





4. Remove the special tool.

Manual transmission vehicles

5. Install the clutch.

Automatic transmission vehicles





6. NOTE: The upper 2 transmission-to-engine bolts will be installed later.

Install the lower 5 transmission-to-engine bolts.
- Tighten to 60 Nm (44 ft. lbs.).





7. Position the shift cable bracket and install the bolts and connect the shift cable.
- Tighten to 25 Nm (18 ft. lbs.).





8. Install 4 new torque converter-to-flexplate nuts.
- Tighten to 36 Nm (27 ft. lbs.).





9. Install the cylinder block opening cover.





10. Install the flexplate inspection cover and the 2 bolts.
- Tighten to 34 Nm (25 ft. lbs.).

11. Install the starter.





12. Position the transmission cooler tube support bracket and install the bolt.
- Tighten to 10 Nm (89 inch lbs.).

All vehicles





13. If equipped, connect the block heater electrical connector.





14. NOTE: LH shown, RH similar.

Connect the LH and RH heated exhaust gas oxygen sensor (H02S) electrical connector and attach the electrical connector retainer.





15. Attach the starter electrical harness support bracket.





16. Connect the oil temperature sensor electrical connector.





17. Position the A/C compressor and install the 3 bolts.
- Tighten to 25 Nm (18 ft. lbs.).





18. Install the 4 exhaust manifold flange nuts.
- Tighten to 40 Nm (30 ft. lbs.).

Automatic transmission vehicles





19. Install the upper 2 transmission-to-engine bolts.
- Tighten to 60 Nm (44 ft. lbs.).





20. Position the transmission filler tube and install the bolt.
- Tighten to 20 Nm (15 ft. lbs.).

All vehicles





21. Connect the crankshaft position (CKP) sensor wiring harness retainer to the starter motor wiring harness.





22. Connect the generator wiring harness retainer to the RH cylinder head.





23. Connect the A/C compressor and the A/C high pressure cut-off switch electrical connectors.





24. Connect the generator wiring harness retainer to the RH cylinder head.





25. Position the power steering pump assembly and install the 3 bolts.
- Tighten to 25 Nm (18 ft. lbs.).





26. Using the special tool, install a new O-ring seal on the pressure line fitting.





27. Connect the power steering pressure tube.
- Tighten to 65 Nm (48 ft. lbs.).





28. Using the special tool, install the power steering pump pulley.





29. Position the power steering pressure hose support bracket and install the nut.
- Tighten to 10 Nm (89 inch lbs.).





30. Position the power steering reservoir assembly and install the bolt.
- Tighten to 23 Nm (17 ft. lbs.).





31. Using a new O-ring seal, connect the A/C manifold and tube assembly and install the nut.
- Tighten to 25 Nm (18 ft. lbs.).





32. Position the A/C manifold and tube assembly support bracket and install the nut.
- Tighten to 25 Nm (18 ft. lbs.).





33. Connect the heater hose.





34. Disconnect the coolant hose.





35. Connect the electrical connector and position the ground strap and install the bolt.
^ Tighten to 10 Nm (89 inch lbs.).





36. Position the cowl extension panel and install the bolts.





37. Attach the wiring harness and the windshield washer hose retainers to the cowl panel extension.
38. Install the intake manifold.
39. Install the radiator.
40. Install the powertrain control module (PCM).
41. Install the cowl.
42. Install the hood.
43. Fill the crankcase with clean engine oil.
44. Evacuate and charge the A/C system.
45. Fill and bleed the power steering system.