Installation
1. Install exhaust manifold gasket and exhaust manifold. Tighten exhaust manifold bolts to 20-30 N-m (15-22 lb-ft) in sequence.
2. Install EGR valve to exhaust manifold tube.
3. Connect EGR valve to exhaust manifold tube to EGR valve, LH exhaust manifold and DPFE hose.
4. Install RH and LH front engine support insulators on cylinder block.
5. Install engine lifting bracketry from Rotunda Engine Lifting Kit 014-00340 or equivalent.
Engine Lifting Brackets, RH Side
Engine Lifting Brackets, LH Side
6. Remove engine from stand using spreader bar and chains from Rotunda Engine Lifting kit 014-00340 or equivalent.
7. Install transmission to cylinder block. Tighten transmission mounting bolts to 40-60 N-m (30-44 lb-ft).
8. Position engine and transmission on front sub4rame.
9. Install front engine support insulator through bolts. Tighten to 20-30 N-m (15-22 lb-ft).
10. Raise engine, transmission and front sub-frame into position.
11. Align front sub4rame to body and install subframe-to-body bolts. Tighten to 95-130 N-m (73-100 lb-ft).
12. Connect steering coupling at pinch bolt joint.
13. Install rear engine support insulator retaining bolts. Tighten to 20-30 N-m (15-22 lb-ft).
14. Remove Rotunda Powertrain Lift 014-00765 or equivalent and position out of way.
15. Install starter motor. Refer to Starting System. Starting System
16. Connect low oil level sensor to engine control sensor wiring.
17. Install starter cable and two retaining nuts to lower engine front cover studs.
18. Install driveshaft to transmission.
19. Lift rear axle assembly into position.
20. Install two nut and bolt assemblies retaining front of the rear axle assembly to the rear sub-frame. Tighten to 98-120 N-m (72-89 lb-ft).
21. Tighten two rear axle differrential nuts to 102-127 N-m (75-89 lb-ft).
22. Align driveshaft centering socket yoke to rear axle universal joint flange and install four retaining bolts. Tighten to 95-130 N-m (70-95 lb-ft).
23. Connect lower oil cooler tube to radiator. Refer to Automatic Transmission-4R70W. Automatic Transmission/Transaxle
24. Connect engine control sensor wiring and shift linkage. Refer to Automatic Transmission-4R70W. Automatic Transmission/Transaxle
25. Position front suspension lower arms to strut and install retaining bolt. Tighten to 160-220 N-m (118-162 lb-ft).
26. Install lower upper radiator hose.
27. Connect power steering pressure hose. Refer to Steering System. Steering
28. Connect ground strap to RH front fender apron.
29. Install dual converter Y pipe. Refer to Exhaust System. Exhaust System
30. Connect front suspension upper arms to front wheel hub and spindles. Tighten to 68-92 N-m (50-68 lb-ft).
31. Connect ride height sensor wiring connectors.
32. Install front disc brake calipers. Refer to Brakes and Traction Control. Brakes and Traction Control
33. Install front wheel and tires. Refer to Wheels and Tires. Wheels and Tires
34. Lower vehicle.
35. Connect NC lines to A/C compressor. Refer to Heating and Air Conditioning. Heating and Air Conditioning
36. Remove engine lifting brackets from Rotunda Engine Lifting Kit 014-00340 or equivalent.
37. Connect upper transmission oil cooler inlet tube. Refer to Automatic Transmission-4R70W. Automatic Transmission/Transaxle
38. Install power steering pump. Connect power steering return line hose to power steering pump. Connect power steering supply hose. Refer to Steering System. Steering
39. Install radiator overflow hose to radiator coolant recovery reservoir.
40. Connect upper radiator hose at water bypass tube.
41. Connect heater inlet and outlet hoses.
42. Connect chassis vacuum supply hose.
43. Connect canister purge vacuum line.
44. Connect accelerator cable and speed control actuator.
45. Connect engine control sensor wiring to fuel vapor canister purge regulator valve.
46. Connect generator B+ wiring connector and install power distribution box and harness.
47. Connect 42-pin connector.
48. Install 42-pin connector to retaining bracket.
49. Connect fuel tubes. Refer to Fuel Delivery and Air Induction. Fuel Delivery and Air Induction
50. Install radiator electric motor, fan blade and fan shroud as an assembly. Refer to Cooling System. Cooling System
51. Install windshield wiper module. Refer to Wiper and Washer Systems. Wiper and Washer Systems
52. Install air cleaner outlet tube and engine air intake resonator.
53. Connect IAT sensor connector and crankcase ventilation tube.
54. Fill crankcase with specified oil.
55. Fill power steering pump. Refer to Steering System. Steering
56. Fill radiator with coolant. Refer to Cooling System. Cooling System
57. Start engine and check for leaks.
58. Top off all fluid levels.
59. Recharge air conditioning system. Refer to Heating and Air Conditioning. Heating and Air Conditioning
60. Install engine appearance cover.
61. Check front end alignment. Refer to Suspension System. Suspension