Part 1
Engine
Installation (Steps 1-35)
All engines
1. Position the engine in the vehicle.
2. Remove the floor crane and the jack supporting the transmission.
3. NOTE: Align the engine-to-transmission dowels before installing the engine-to-transmission bolts.
Position the shifter cable support bracket and install the 2 transmission-to-engine bolts.
^ Tighten to 60 Nm (44 lb-ft).
4. Install the RH lower transmission-to-engine bolt.
^ Tighten to 60 Nm (44 lb-ft).
5. NOTE: RH shown, LH similar.
Install the 4 engine support insulator-to-crossmember nuts.
^ Tighten to 90 Nm (66 lb-ft).
6. Position the mounting bracket, install the 2 bolts and connect the shift cable.
^ Tighten to 25 Nm (18 lb-ft).
7. Install 4 new torque converter nuts.
^ Rotate the crankshaft to access all of the torque converter nuts.
^ Tighten to 35 Nm (26 lb-ft).
8. Install the cylinder block opening cover.
9. Position the flexplate inspection cover and install the 2 bolts.
^ Tighten to 34 Nm (25 lb-ft).
10. If equipped, install the A/C compressor and the 3 bolts.
^ Tighten to 25 Nm (18 lb-ft).
11. Position the exhaust Y-pipe and install the 4 nuts.
^ Tighten to 40 Nm (30 lb-ft).
12. CAUTION: The oil cooler must be replaced or severe damage to the engine can occur.
NOTE: Make sure the tab on the oil filter adapter nests into the notch in the oil cooler.
Position a new oil cooler on the oil filter adapter and install the threaded insert.
^ Tighten to 58 Nm (43 lb-ft).
13. Install a new oil filter.
^ Tighten to 16 Nm (12 lb-ft).
14. Connect the 2 oil cooler coolant hoses.
4.6L (2V) engine
15. Position the transmission fluid cooler tube support bracket and install the nut.
^ Tighten to 10 Nm (89 lb-in).
5.4L (2V) engine
16. Position the fluid cooler tube support bracket and install the nut.
^ Tighten to 28 Nm (21 lb-ft).
All engines
17. Using the special tool, install a new Teflon(R) seal on the power steering pressure tube.
18. Connect the power steering pressure tube and the power steering reservoir hose to the power steering pump.
^ Tighten to 20 Nm (15 lb-ft).
19. Install the oil drain plug.
^ Tighten to 23 Nm (17 lb-ft).
20. Position the fuel line and the LH heated oxygen sensor (HO2S) brackets and install the 4 upper transmission-to-engine bolts.
^ Tighten to 60 Nm (44 lb-ft).
21. Connect the transmission wiring harness and the LH and RH HO2S electrical connectors. Install the transmission wiring harness connector retainer in the bracket.
22. NOTE: Do not reuse the O-ring seals. Lubricate the new O-ring seals with clean engine coolant prior to installing the heater outlet tube.
Insert the heater outlet tube over the new seals.
5.4L (2V) engine
23. Install the heater outlet tube studs.
^ Tighten to 40 Nm (30 lb-ft).
24. Connect the coolant hose to the heater outlet tube.
25. Install the wiring retainers in the heater outlet tube bracket.
1 Install the knock sensor (KS) electrical connector retainer.
2 Install the engine harness routing clip retainer.
All engines
26. Connect the evaporative emission (EVAP) canister purge valve electrical connector.
27. Connect the attachments to the transmission fluid filler tube and install the fluid level indicator.
1 Connect the rear heater hose hanger.
2 Install the fluid level indicator.
28. Install the engine oil filler tube support strap bolt.
^ Tighten to 9 Nm (80 lb-in).
29. Position the mounting bracket, install the ground strap and nut, and connect the electrical connectors to the bracket.
^ Tighten to 25 Nm (18 lb-ft).
30. Connect the engine wiring harness electrical connectors.
31. Connect the PCM electrical connectors.
32. Connect the engine wiring harness to the PCM bracket.
33. Position the generator and install the bolts.
^ Tighten to 25 Nm (18 lb-ft).
34. Connect the generator electrical connections.
1 Tighten the B+ terminal nut to 8 Nm (71 lb-in).
2 Connect the S electrical connector.
3 Connect the ASI electrical connector.
35. Rotate the tensioner clockwise and install the accessory drive belt. Refer to the decal on the upper radiator air deflector for belt routing.
