Installation
Installation Procedure1. Install the left and right exhaust manifolds.
2. Install and connect the engine wiring harness to the engine.
3. Install the lifting device to the engine.
4. Remove the engine from the engine stand.
5. Install the engine flywheel.
6. Install the engine to the transmission.
Notice: Refer to Fastener Notice in Service Precautions
7. For the manual transmission, install the flywheel housing to engine bolts (1, 2) and nuts (3).
Tighten the flywheel housing to engine bolts (1, 2) and nuts (3) to 95 Nm (70 ft. lbs.).
8. If equipped with a automatic transmission remove the J 21366 from the transmission.
9. For the automatic transmission, install the transmission to engine bolts and nut.
Tighten the transmission to engine bolts and nut to 95 Nm (70 ft. lbs.).
10. Connect the electrical connectors to the transmission.
11. If equipped with the manual transmission install left side transmission support (1).
12. Install the left side transmission support brace bolts (2, 3).
^ Tighten the left side transmission support brace bolts (2) to the transmission to 50 Nm (37 ft. lbs.).
^ Tighten the left side transmission support brace bolts (3) to the engine to 28 Nm (21 ft. lbs.).
13. If equipped with the manual transmission install right side transmission support (1).
14. Install the right side transmission support brace bolts (3, 4).
Tighten the right side transmission support brace bolts (3, 4) to 50 Nm (37 ft. lbs.).
15. If equipped with the Automatic transmission install left side transmission support (4).
16. Install the left side transmission support bolts (3, 5).
17. Install the left side transmission support nut (1). Tighten
^ Tighten the left side transmission support bolt (3) to 8.5 Nm (75 inch lbs.).
^ Tighten the left side transmission support bolt (5) to 28 Nm (21 ft. lbs.).
^ Tighten the left side transmission support nut (1) to 80 Nm (59 ft. lbs.).
18. If equipped with the automatic transmission install right side transmission support (4).
19. Install the right side transmission support brace bolts (1, 2, 3).
20. Install the right side transmission support nut (6).
^ Tighten the right side transmission support brace bolt (1) to 8.5 Nm (75 inch lbs.).
^ Tighten the right side transmission support bolts (2,3) to 50 Nm (37 ft. lbs.).
^ Tighten the right side transmission support nut (6) to 80 Nm (59 ft. lbs.).
21. With the aide of an assistant, lower the engine and transmission to the crossmember.
22. Install the left engine mount bracket (1) and mount bracket stud (2).
23. Install the left engine mount bracket bolts (3).
^ Tighten the left engine mount bracket bolt (3) to 102 Nm (75 ft. lbs.).
^ Tighten the left engine mount bracket stud (2) to 87 Nm (64 ft. lbs.).
24. Install the right engine mount bracket (3) and the engine mount bracket bolts (1, 2).
^ Tighten the two right engine mount bracket bolts (1) to 102 Nm (75 ft. lbs.).
^ Tighten the right engine mount bracket bolt (2) to 50 Nm (37 ft. lbs.).
25. Remove the lifting device from the engine.
26. Install the generator to the engine.
27. Install the positive cable nut to the generator terminal.
Tighten the positive cable nut to generator terminal to 22 Nm (16 ft. lbs.).
28. Connect the generator electrical connector.
29. Install the power steering pump.
30. Install the power steering pump nuts (3).
Tighten the power steering nuts (3) to 30 Nm (22 ft. lbs.).
31. Install the A/C compressor bracket and compressor.
32. Install the drive belt tensioner.
33. Remove the safety straps from the crossmember and J 39580.
34. Lower the vehicle and install the engine and transmission to the vehicle.
35. Align the crossmember to the vehicle body.
36. Install the front crossmember bolts.
^ Tighten the four crossmember bolts to 125 Nm (92 ft. lbs.).
^ Tighten the two crossmember bolts to 145 Nm (107 ft. lbs.).
37. Install the transmission support bolts.
^ Tighten the transmission support bolts to 57 Nm (42 ft. lbs.).
38. Raise the vehicle.
39. Remove the J 39580 from under the vehicle.
40. Install the ball joints to the steering knuckles.
41. Install the left and right upper ball joint nuts.
Tighten the upper ball joint nuts to 53 Nm (39 ft. lbs.).
42. Install the cotter pins to the left and right upper ball joints.
43. Instal the right and left side shock absorber lower mounting bolts.
Tighten the shock absorber lower mounting bolts to 65 Nm (48 ft. lbs.).
44. Lower the vehicle.
45. If equipped with the manual transmission Install the transmission control.
46. Install the engine wire harness through the front of the cowl.
47. Connect the engine wiring harness to the instrument panel wiring harness.
48. Install the hinge pillar trim panel.
49. Install the right side insulator panel.
50. Install the PCM.
51. Install the engine harness vacuum tube to the bottom of the vacuum check valve.
52. Connect the forward lamp harness to the engine harness.
53. Install the front 2 brake pipes to the brake modulator.
54. Install the brake booster vacuum hose (2) to the intake manifold fitting (1).
55. Install the outlet hose to the coolant pump.
56. Install the inlet hose to the water outlet.
57. Install the forward lamp harness to the wiring harness clip.
58. Connect the Electronic Throttle Control (ETC) electrical connector (1).
59. Install the fuel vapor line (4) to the EVAP canister purge valve (5).
60. Install the fuel pipes (2) to the fuel rail.
61. Install the heater hoses to the drive belt tensioner.
62. Install a new O-Ring.
63. Install the A/C compressor and condenser hose bolt to the accumulator.
Tighten A/C compressor and condenser hose bolt at the accumulator to 48 Nm (36 ft. lbs.).
64. Install the engine ground.
65. Install the engine wiring harness ground bolt (1).
Tighten the engine wiring harness ground bolt to 25 Nm (18 ft. lbs.).
66. Raise the vehicle.
67. Install the brake lines to the brake pipe clip.
68. Install the front fuel pipe heat shield (2).
69. Install the front fuel pipe heat shield nuts (1).
Tighten the front fuel pipe heat shield nuts (1) to 5 Nm (44 inch lbs.).
70. Install a new O-Ring.
71. Install the A/C compressor and condenser hose nut to the condenser.
Tighten the A/C compressor and condenser hose nut to the condenser to 16 Nm (12 ft. lbs.).
72. Install a new O-Ring.
73. Install the A/C compressor and condenser hose bolt to the compressor.
Tighten the A/C compressor and condenser hose bolt to 33 Nm (24 ft. lbs.).
74. Connect the wheel speed sensors electrical connectors.
75. Connect the knock sensors electrical connectors.
76. Install the RF ground strap, cruise control lead and wiring harness ground bolt to the front rail.
Tighten the wiring harness ground bolt to 12 Nm (106 inch lbs.).
77. Install the intermediate steering shaft and bolt to the rack.
78. Install the stabilizer bar brackets.
79. Install the left side front air deflector.
80. On vehicles equipped with a manual transmission, install the clutch actuator cylinder line to the actuator cylinder.
81. If equipped with a automatic transmission, install the range selector lever cable to the cable bracket.
82. Install the retainer to the range selector lever cable.
83. Install the transmission range selector lever cable to the transmission range selector.
84. Install the torque arm.
85. Install the propeller shaft.
86. Install the 3-way catalytic converter.
87. Install the front wheels.
88. If equipped install the torque converter to flywheel bolts.
89. Install the starter motor.
90. Lower the vehicle.
91. Install the air intake duct.
92. Connect the Intake Air Temperature (IAT) sensor electrical connector.
93. Install the positive battery cable to the battery.
Tighten the positive battery terminal to 15 Nm (11 ft. lbs.).
94. Install the negative battery cable to the battery.
Tighten the negative battery terminal to 15 Nm (11 ft. lbs.).
95. Fill the crankcase with engine oil.
96. Check and fill the transmission fluid as necessary.
97. Refill the engine coolant.
98. Recharge the A/C system.
99. Bleed the brakes.
100. Bleed the clutch hydraulic system.
101. Perform the Crankshaft Position (CKP) system variation learn procedure.