Engine - Installation

INSTALLATION






NOTE: Do not use air tools to install Engine Lift Fixture 8984A (1) and Adapter 8984-UPD (2).

1. Install engine lift fixture (1) Special tool 8984A and adapter (2) Special tool 8984-UPD.
2. Position engine in the engine compartment.





3. Lower and align engine (1) with the transmission (3).
4. Install two transmission to engine block mounting bolts (2) finger tight.





5. Lower the engine assembly until the engine mounts (2) lineup in the frame brackets (1).





6. Install the remaining transmission bell housing to engine block mounting bolts (2) and tighten to 68 Nm (50 ft.lbs.).





7. Install both the left and right side oil pan to transmission bolts (1) and tighten bolts to 54 Nm (40 ft. lbs.).





8. Install engine mount through bolts (3) and nuts and tighten bolts to 95 Nm (70 ft. lbs.).





9. Install all torque converter-to-driveplate bolts (1) by hand, verify the torque converter is pulled flush to the driveplate and tighten bolts to 31 Nm (270 in. lbs.).






CAUTION: The structural dust cover must be installed as described in the Structural Dust Cover installation procedure. Failure to do so will cause severe damage to the cover.

10. Install the structural dust cover (1) Structural Dust Cover - Installation





11. Install the starter (1) and connect the starter wires Starter - Installation





12. Install the front exhaust pipe/catalytic converter assembly (3) to the exhaust manifold flange and tighten the bolts (2) and nuts (1) to 26 Nm (19 in. lbs.).





13. Remove the engine lift fixture (1) 8984A and adapter (2) 8984-UPD.
14. Connect the fuel supply line Service and Repair
15. Install the power steering pump Power Steering Pump - Installation
16. Connect the ground wires to the rear of each cylinder head.
17. Install the intake manifold Intake Manifold - Installation





18. Install the generator (2), and wire connections Generator - Installation





19. Install the a/c compressor (3) A/C Compressor - Installation





20. Connect the refrigerant lines (1,3) to the A/C compressor (4) and tighten the nuts (2) to 20 Nm (15 ft. lbs.).





21. Install the accessory drive belt Serpentine Accessory Drive Belt - Installation

CAUTION: Before installing the radiator or A/C condenser, be sure the radiator-to-body and radiator-to-A/C condenser rubber air seals are properly fastened to their original positions. These are used at the top, bottom and sides of the radiator and A/C condenser. To prevent overheating, these seals must be installed to their original positions.

22. Install the condenser A/C Condenser - Installation

NOTE: The lower part of radiator is equipped with two alignment dowel pins. They are located on the bottom of radiator tank and fit into rubber grommets. These rubber grommets are pressed into the radiator lower crossmember.

23. Install the radiator and cooling fan as an assembly Engine Cooling Radiator - Installation

NOTE: When ever the high pressure line fittings are removed from the hydraulic fan drive the O-rings must be replaced.

24. Lubricate the new O-rings on the fittings with power steering fluid then connect inlet and outlet high pressure lines to fan drive. Tighten inlet line to 49 Nm (36 ft. lbs.) tighten outlet line to 29 Nm (22 ft. lbs.) Cooling Fan - Installation
25. Install the upper crossmember and top core support.




26. Connect the heater hoses (2).
27. Connect the radiator hose (1).
28. Connect the transmission oil cooler lines.





29. Connect the refrigerant lines (1) to the A/C condenser A/C Discharge Line - Installation and A/C Liquid Line - Installation
30. Connect the upper radiator hose.
31. Fill crankcase with engine oil and install new oil filter Engine Oil Filter - Installation
32. Fill cooling system Service and Repair





33. Install the engine cover (1).





34. Install the air cleaner resonator and duct work as an assembly (1).
35. Connect IAT sensor electrical connector (2).





36. Install the strut tower support (1).

37. Install the hood Hood - Installation
38. Connect the negative battery cable.
39. Charge the refrigerant system Refrigerant System Charge
40. Start the engine and inspect for leaks.
41. Road test vehicle.