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 to EGR valve and LH exhaust manifold. Tighten retaining nuts to 40-45 N-m (30-33 lb-ft).











3. Connect EGR pressure sensor hoses to the EGR valve to exhaust manifold tube.

4. Install RH and LH front engine support insulators on cylinder block.

5. Install engine lifting bracketry from Rotunda Engine Lift Bracket Set 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 Lift Bracket Set 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 sub-frame.

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 sub-frame-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 move 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 positive battery 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 sub4rame. Tighten to 98-120 N-m (72-89 lb-ft).

21. Tighten two rear axle differential nuts to 102-127 N-rn (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 (70-96 lb-ft).

23. Connect lower oil cooler tube to radiator. Refer to Automatic Transmission-4R70W. Automatic Transmission/Transaxle

24. Connect engine control sensor wiring.

25. Connect gear selector linkage. Refer to Automatic Transmission-4R70W. Automatic Transmission/Transaxle

26. Position front suspension lower arms to strut and install retaining bolt. Tighten to 160-220 N-m (118-162 lb-ft).

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 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 A/C lines to A/C compressor. Refer to Heating and Air Conditioning. Heating and Air Conditioning

36. Remove engine lifting brackets from Rotunda Engine Lift Bracket Set 014-00340 or equivalent.

37. Connect upper 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 pressure 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 evaporative emission canister purge valve.

46. Connect generator B+ winng connector and install power distribution box and harness.

47. Connect 42-pin connector.

48. Install engine appearance cover as previously outlined.






49. Install 42-pin connector to retaining bracket.

50. Connect fuel tubes. Refer to Fuel Delivery and Air Induction. Fuel Delivery and Air Induction

51. Install cooling fan, fan blade and fan shroud assembly. Refer to Cooling System. Cooling System

52. Install windshield wiper module assembly. Refer to Wiper and Washer Systems. Wiper and Washer Systems

53. Install air cleaner outlet tube and engine air intake resonator.

54. Connect IAT sensor wiring connector and crankcase ventilation tube.

55. Fill crankcase to proper level with specified oil.

56. Fill power steering pump. Refer to Steering System. Steering

57. Fill radiator with engine coolant. Refer to Cooling System. Cooling System

58. Start engine and check for leaks.

59. Recheck all fluid levels. Fill as required.

60. Evacuate and recharge air conditioning system. Refer to Heating and Air Conditioning. Heating and Air Conditioning

61. Install engine appearance cover.

62. Check front end alignment. Refer to Suspension System. Suspension