Installation

INSTALLATION

Engine

Special Tool(s):

Material:

Installation

Vehicles equipped with an automatic transmission

1. NOTE: Make sure the marks made on the torque converter stud and the flexplate are lined up.

Position the engine in the vehicle and mate it to the transmission.

Vehicles equipped with a manual transmission
2. Position the engine with the front of the engine facing the LH side of the vehicle. Lower the engine until the generator pulley is slightly higher than the radiator upper support.





3. Turn the engine 90 degrees to the right, lower the engine and mate it to the transmission.





All vehicles

4. CAUTION: Clean the engine support insulator-to-bracket mating surfaces and the bolt holes in the bracket of any dirt or foreign material prior to installation.

Install the RH engine support insulator and the bolts.
^ Apply threadlock to the bolts threads prior to installation.
^ Tighten to 115 Nm (85 ft. lbs.). Remove the floor jack and wood block from the transmission.





5. CAUTION: Clean the engine support insulator-to-bracket mating surfaces and the bolt holes in the bracket of any dirt or foreign material prior to installation.

Install the LH engine support insulator and the bolts.
^ Apply threadlock to the bolts threads prior to installation.
^ Tighten to 115 Nm (85 ft. lbs.).





6. Remove the floor jack and wood block from the transmission.
7. Lower the engine into position and remove the floor crane and the special tools.
8. Position the power steering fluid reservoir bracket and install the bolts.
^ Tighten to 20 Nm (15 ft. lbs.).





9. CAUTION: Make sure the RH engine support insulator mating surfaces and the washer mating surface are free of foreign material and corrosion before installation. Install a new washer.

Install the RH engine support insulator nuts and washer.
^ Tighten to 250 Nm (184 ft. lbs.).





10. Install the LH engine support insulator through bolt.
^ Tighten to 350 Nm (258 ft. lbs.).





11. Install the transmission-to-engine bolts.
^ Tighten to 47 Nm (35 ft. lbs.).





12. Install the 3 oil pan-to-transmission bolts.
^ Tighten to 34 Nm (25 ft. lbs.).





Vehicles equipped with an automatic transmission

13. NOTE: Rotate the crankshaft using the crankshaft pulley bolt to access all of the torque converter nuts.

Install the 4 torque converter nuts.
^ Tighten to 36 Nm (27 ft. lbs.).





14. Install the cylinder block opening cover.





All vehicles
15. Install the starter motor.

16. Install the 4 three-way catalytic converter nuts.
^ Tighten to 40 Nm (30 ft. lbs.).





17. If equipped, connect the engine block heater electrical connector.





18. Position the starter wiring harness bracket and install the nut.
^ Tighten to 20 Nm (15 ft. lbs.).





Vehicles equipped with an automatic transmission
19. Attach the transmission cooler tubes to the bracket.





All vehicles
20. Install a new oil filter.
^ Tighten to 16 Nm (12 ft. lbs.).





21. NOTE: Do not tighten the bolts until the 2 upper bolts are installed.

NOTE: Make sure the power steering pressure hose bracket is installed on the stud.

Position the power steering pump and install the bolts finger tight.
1 Slide the power steering pump into position while installing the front bolt.
2 Install the bolt.





22. Attach the wiring harness retainer to the rear of the RH cylinder head.





23. Position the ground wire and install the bolt.





24. Connect the wiring harness in-line connector.





25. Connect the positive crankcase ventilation (PCV) valve hose to the PCV valve.





26. Position the coil and the RH spark plug wires as an assembly and install the bolts.
^ Tighten to 7 Nm (62 inch lbs.).

27. Connect the coil electrical connector.





28. Attach the RH spark plug wire retainers.





29. Apply silicone dielectric compound to the inside of the spark plug wire boots. Connect the spark plug wires to the spark plugs.
30. Attach the wiring harness retainer.





31. Connect the generator.
^ Connect the electrical connector.
^ Connect the battery positive cable, install the nut and slide the protective cap over the terminal.
- Tighten to 8 Nm (71 inch lbs.).
^ Attach the wiring harness retainer.





32. NOTE: Tighten the lower bolts at this time.

Install the power steering pump upper bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





33. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.





34. If equipped, install the compressor manifold and tube assembly.
35. Position the power steering fluid reservoir and install the bolts.
^ Tighten to 10 Nm (89 inch lbs.).





36. Position the LH spark plug wires and attach the LH spark plug wire retainers.





37. Apply silicone dielectric compound to the inside of the spark plug wire boots. Connect the spark plug wires to the spark plugs.

Vehicles equipped with an automatic transmission
38. Connect the fuel vapor tubes to the purge valve.





All vehicles
39. Position the fuel rail, the fuel injectors, the fuel charging wiring harness and the vacuum harness as an assembly and install the bolts.
^ Tighten to 10 Nm (89 inch lbs.).





40. Connect the fuel supply spring lock coupling.
41. Connect the intake manifold runner control (IMRC) actuator and the fuel charging wiring harness electrical connectors.





42. Connect the lower radiator hose to the coolant pump.





43. Connect the heater hoses.





44. Connect the upper radiator hose to the thermostat housing.





45. Install the air cleaner.
46. Install the radiator and the cooling fan and shroud.
47. Install the upper intake manifold.
48. Position the radiator sight shield and install the 9 pushpins.





49. Position the cowl extension panel and install the 7 bolts.





Vehicles equipped with a manual transmission
50. Connect the fuel vapor tubes to the purge valve. Position the clutch master cylinder reservoir and install the pushpins.





All vehicles
51. Attach the windshield washer hose, the wiring harness retainer and the electrical connector to the cowl extension panel.





52. Install the powertrain control module (PCM).
53. Install the cowl panel grille.
54. Position the hood and install the bolts.
^ Tighten to 30 Nm (22 ft. lbs.).

55. Connect the battery ground cable.
56. Fill the engine with clean engine oil.
57. Fill and bleed the cooling system.
58. If equipped, evacuate and charge the A/C system.