Installation
INSTALLATION1. Remove the oil filter.
2. Lift the engine off the stand and lower it into the engine compartment. For easier installation, it may be useful to remove the engine support cushions from the engine support brackets as an aide for alignment of the engine-to-transmission.
Manual Transmission To Engine-4.0L:
3. If equipped with a manual transmission, perform the following:
a. Lower engine into compartment.
b. Insert the transmission shaft into the clutch spline.
c. Align the flywheel housing with the engine.
d. Install and tighten the flywheel housing bolts to 38 Nm (28 ft. lbs.).
Automatic Transmission To Engine-4.0L:
4. If equipped with an automatic transmission, perform the following:
a. Align converter housing with engine.
b. Install and tighten the converter housing bolts to 38 Nm (28 ft. lbs.).
c. Install and tighten the torque converter to flex plate bolts to 68 Nm (50 ft. lbs.).
5. Remove the floor jack or support stand from beneath the flywheel/converter housing.
6. Lower the engine and engine support cushions onto the engine compartment brackets. Ensure that the bolt holes are aligned. Install the thru-bolts and nuts and tighten to 81 Nm (60 ft. lbs.).
7. Remove the engine lifting device.
8. Raise the vehicle.
9. Install inspection cover and tighten bolts/nuts to 16 Nm (138 inch lbs.)
10. Attach the exhaust pipe to the manifold. Install and tighten the nuts to 31 Nm (23 ft. lbs.) torque.
11. Install the starter motor and bolts. Tighten the bolts to 45 Nm (33 ft. lbs.).
12. Install the oil filter.
13. Lower the vehicle.
14. If equipped with power steering:
a. Remove the protective caps
b. Connect the hoses to the fittings at the steering gear. Tighten the nut to 52 Nm (38 ft. lbs.) torque.
c. Fill the pump reservoir with fluid.
15. Inspect the fuel supply line O-rings and replace if necessary. Install fuel supply line to fuel rail. Push until a "click" is heard. Verify the connection by pulling outward on line. Install latch clip.
16. Attach fuel supply line bracket to intake manifold.
17. Connect the brake booster, HVAC, canister purge, and CCV vacuum hoses to the intake manifold.
18. Connect the following electrical connectors:
^ Power steering pressure switch (if equipped)
^ Coolant temperature sensor at the thermostat housing
^ six (6) fuel injector connectors
^ Intake air temperature sensor
^ Idle air control motor
^ Throttle position sensor
^ MAP sensor
^ Crankshaft position sensor
^ Oxygen sensor
19. Install the engine ground strap.
20. Connect heater hoses to thermostat housing and water pump inlet tube.
21. Connect accelerator cable, transmission line pressure cable (if equipped), and speed control cable (if equipped) to bracket and throttle body.
22. Install the radiator and fan shroud. Tighten fan shroud and radiator fasteners to 8 Nm (75 inch lbs.).
23. Connect transmission cooler lines (if equipped). Tighten fittings to 15 Nm (135 inch lbs.).
24. Install the viscous fan/drive assembly. Tighten nuts to 27 Nm (20 ft. lbs.).
25. Install and tension the accessory drive belt.
26. Install the radiator hoses.
27. Connect the following electrical connectors:
^ Ignition coil
^ Distributor
^ Starter motor
^ A/C compressor clutch (if equipped)
^ A/C Hi-pressure switch (if equipped)
^ Generator
^ Oil pressure sender
^ Harness ground at dipstick tube bracket
28. Remove the coolant temperature sending unit to permit air to escape from the block. Fill the cooling system with coolant. Install the coolant temperature sending unit when the system is filled.
29. Connect A/C suction/discharge hose and recharge A/C system.
30. Install air cleaner resonator and duct work.
31. Lower the hood and secure in place.
32. Start the engine and inspect for leaks.
33. Stop the engine and check all fluid levels. Add fluid, as required.