Installation

Installation Procedure





1. Lay the engine wiring harness on to the engine.
2. Connect the following engine wiring harness electrical connectors:
- Oil level sensor (1)
- CKP sensor (2)





3. Install the vacuum hose (2) to the tee on the rear vacuum port.
4. Connect the MAP sensor electrical connector (1).

Notice: Refer to Fastener Notice in Service Precautions.

5. Install the engine wiring harness clip bolt (3).
- Tighten the engine wiring harness clip bolt to 50 Nm (37 ft. lbs.).





6. Connect the following engine wiring harness electrical connectors:
- Oil pressure sensor (1)
- Knock sensor harness (4)
7. Install engine wiring harness ground bolts (2, 3).
- Tighten the engine wiring harness ground bolts to 50 Nm (37 ft. lbs.).





8. Connect the following engine wiring harness electrical connectors:
- Fuel injectors (2)
- Ignition coil (4)
9. Install the rosebud clips (3) to the fuel rail.
10. Connect the CPA retainer (1).





11. Connect the following engine wiring harness electrical connectors:
- IAC valve
- TP sensor
- Fuel injectors (3)
- Ignition coil (2)
- Canister purge valve (5)
- AIR solenoid
12. Install the rosebud clips (4) to the fuel rail.
13. Connect the CPA retainer (1).





14. Install the right catalytic converter gasket (2) and converter.
15. Install the exhaust manifold pipe nuts (1).
- Tighten the exhaust manifold pipe nuts to 35 Nm (26 ft. lbs.).





16. Install the left catalytic converter gasket (2) and converter.
17. Install the exhaust manifold pipe nuts (1).
- Tighten the exhaust manifold pipe nuts to 35 Nm (26 ft. lbs.).





18. Install the J 41798 to the engine block.
19. Install an engine hoist to the engine block.
20. Remove the engine from the engine stand.





21. Install the manual transmission flywheel, if equipped.





22. Install the automatic transmission flywheel, if equipped.
23. Install the engine flywheel bolts.
23.1. Tighten the engine flywheel bolts a first pass in sequence to 20 Nm (26 ft. lbs.).
23.2. Tighten the engine flywheel bolts a second pass in sequence to 50 Nm (37 ft. lbs.).
23.3. Tighten the engine flywheel bolts a final pass in sequence to 100 Nm (74 ft. lbs.).





24. Install the clutch disc and pressure plate to the flywheel, if equipped.
25. Install the pressure plate bolts until snug, if equipped.
26. Using J 38836, align the clutch disc splines with the pilot bearing.

Pressure Plate Tightening Sequence:

27. Tighten the clutch pressure plate bolts.
- Tighten the clutch pressure plate bolts in sequence (as shown) and evenly over 3 increments with the fourth increment to 70 Nm (52 ft. lbs.).
28. Remove the J 38836.
29. Remove the J 21366 from the automatic transmission.
30. Mate the transmission to the engine.





31. Install the manual transmission bolts (2), if equipped.
- Tighten the manual transmission bolts to 50 Nm (37 ft. lbs.).





32. Install the automatic transmission bolts, if equipped.
- Tighten the automatic transmission bolts to 95 Nm (70 ft. lbs.).
33. Remove the support from the transmission on the J 39580.
34. With the aide of an assistant, position the engine and transmission over the crossmember.
35. Lower the engine using the J 41798.





36. Install the left side engine mount and studs.
- Tighten the engine mount studs to 50 Nm (37 ft. lbs.).





37. Install the engine mount heat shield and nuts.
- Tighten the engine mount heat shield nuts to 10 Nm (89 inch lbs.).





38. Install the right side engine mount and bolts.
- Tighten the engine mount bolts to 50 Nm (37 ft. lbs.).
39. Remove the engine hoist from the J 41798.





40. Install the generator.
41. Install the transmission oil cooler clip and generator bolts until snug.





42. Install the generator rear bracket bolt (1) until snug.
43. Tighten the generator bolts.
- Tighten the generator rear bracket bolt to 25 Nm (18 ft. lbs.).
- Tighten the generator bolts to 50 Nm (37 ft. lbs.).





44. Install the push-in retainer (4) to the manual transmission tab.
45. Connect the following electrical connectors to the left side of the manual transmission, if equipped:
- Skip shift solenoid (1)
- Reverse lockout solenoid (2)
- Vehicle speed sensor (3)





46. Install the rosebud clip (1) to the right side of the manual transmission, if equipped.
47. Connect the back-up lamp switch electrical connector (2).
48. Install the automatic transmission fill tube bolt.
- Tighten the automatic transmission fill tube bolt to 50 Nm (37 ft. lbs.).





49. Install the engine wiring harness clip bolt (1) to the automatic transmission, if equipped.
- Tighten the engine wiring harness clip bolt to 2.5 Nm (22 inch lbs.).
50. Connect the following electrical connectors to the automatic transmission, if equipped:
- 20-way connector (2)
- Vehicle speed sensor (3)





51. Install the torque converter bolts.
- Tighten the torque converter bolts to 63 Nm (47 ft. lbs.).





52. Install the right transmission cover and bolt, if equipped.
- Tighten the transmission cover bolt to 12 Nm (106 inch lbs.).





53. Install the left transmission cover and bolt, if equipped.
- Tighten the transmission cover bolt to 12 Nm (106 inch lbs.).





54. Install the A/C compressor bracket.
55. Install the A/C compressor bracket bolts.
- Tighten the A/C compressor bolts to 50 Nm (37 ft. lbs.).





56. Install the A/C compressor.
57. Install the A/C compressor bolts.
- Tighten the A/C compressor bolts to 50 Nm (37 ft. lbs.).





58. Connect the A/C compressor electrical connector.
59. Install the rosebud clip to the engine bracket.





60. Install the power steering pump bracket and bolts.
- Tighten the power steering pump bracket bolts to 50 Nm (37 ft. lbs.).





61. Position the power steering pump to the engine.
62. Install the power steering pump brace (3) and bolts (4) to the pump (1).
- Tighten the power steering pump bolts to 25 Nm (18 ft. lbs.).





63. Using J25033-C install the power steering pump pulley (1).





64. Install the A/C drive belt around the crankshaft balancer.
65. Install a ratchet with hex-head socket to the A/C belt tensioner bolt.
66. Rotate the A/C drive belt tensioner clockwise in order to relieve tension on the drive belt tensioner.
67. Install the A/C drive belt under the idler pulley.
68. Install the A/C drive belt over the A/C compressor pulley.
69. Slowly release tension on the A/C drive belt tensioner.
70. Remove the ratchet and socket from the A/C drive belt tensioner bolt.





71. Route the accessory drive belt around all the pulleys except the water pump pulley and tensioner.
72. Install a ratchet with hex-head socket to the drive belt tensioner bolt.
73. Rotate the drive belt tensioner clockwise in order to relieve tension on the accessory drive belt tensioner.
74. Install the accessory drive belt under the water pump pulley.
75. Install the accessory drive belt onto the drive belt tensioner.
76. Slowly release the tension.
77. Remove the ratchet and socket from the drive belt tensioner bolt.





78. Remove the J 41798 from the engine.
79. Install the ignition coil(s) (as required).





80. Ensure that the crossmember is still secured to the J 39580.
81. Carefully lower the vehicle onto the engine and transmission assembly.





82. Install the transmission crossmember bolts.
- Tighten the transmission support bolts to 57 Nm (42 ft. lbs.).
83. Install the front crossmember bolts.
- Tighten the four upper crossmember bolts to 125 Nm (92 ft. lbs.).
- Tighten the two lower crossmember bolts to 145 Nm (107 ft. lbs.).
84. Remove the security straps from the vehicle.
85. Separate the engine wire harness branches.
86. Raise the vehicle until the crossmember is off the J 39580.
87. Remove the J 39580.





88. Clip the brake lines to the brake pipe clip.
89. Close the fuel pipe clip (7).
90. Install the front fuel pipe heat shield (2).
91. Install the front fuel pipe heat shield nuts (1).
- Tighten the front fuel pipe heat shield nuts to 5 Nm (44 inch lbs.).





92. Unsecure both steering knuckles.
93. Install the left and right upper control arm nuts.
- Tighten the upper control arm nuts to 53 Nm (39 ft. lbs.).
94. Install new cotter pins.





95. Install the right and left side shock absorber lower bolts.
- Tighten the shock absorber bolts to 65 Nm (48 ft. lbs.).
96. Install the starter motor.





97. Install the positive lead to the generator.
98. Install the battery positive cable nut to the generator output stud.
- Tighten the engine wiring harness generator output stud nut to 22 Nm (16 ft. lbs.).
99. Position the generator output terminal boot over the terminal.





100. Connect the left and right side wheel speed sensor electrical connectors.





101. Install the intermediate steering shaft to the power steering rack.
102. Install the intermediate steering shaft bolt.
- Tighten the intermediate steering shaft bolt to 47 Nm (35 ft. lbs.).
103. Install the torque arm.
104. Install the propeller shaft.





105. Connect the master cylinder hose to the clutch actuator hose, if equipped.





106. Snap the automatic transmission range selector lever cable to the bracket, if equipped.





107. Install the automatic transmission range selector lever cable retainer, if equipped.





108. Snap the automatic transmission range selector lever cable to the range selector lever, if equipped.





109. Position the RF ground strap and cruise control ground lead to the frame rail.
110. Install the engine wiring harness ground bolt.
- Tighten the engine wiring harness ground bolt to 12 Nm (106 inch lbs.).





111. Install the stabilizer bar brackets.
112. Install the stabilizer bar bracket bolts/stud.
- Tighten the stabilizer bar bracket bolts/stud to 55 Nm (41 ft. lbs.).
113. Install the drive side front fascia air deflector.
114. Install the exhaust crossover pipe.
115. Connect ALL oxygen sensor electrical connectors.
116. Install the front wheels.





117. Install the lower oil cooler line to the radiator.
- Tighten the lower oil cooler line fitting to 27 Nm (20 ft. lbs.).





118. Lower the vehicle.
119. Pull the engine wiring harness through the front of dash.





120. Connect the engine wiring harness to the instrument panel wiring harness.
121. Remove the hinge pillar trim panel.
122. Remove the right side insulator panel.





123. Install the PCM to the bracket.
124. Connect the PCM connectors.
- Tighten the PCM connector bolts to 8 Nm (71 inch lbs.).





125. Connect the engine harness vacuum tube to the bottom of the vacuum check valve.
126. Connect the forward lamp harness to the engine harness.
127. Connect the secondary captured locks.
128. Install the front two brake lines to the brake pressure modulator valve.
- Tighten the brake pipe fittings to 15 Nm (11 ft. lbs.).
129. Install the brake booster vacuum hose.





130. Install the AIR hose (2) to the AIR shut-off valve (1).





131. Install and snap the accelerator and cruise control cable to the throttle body bracket.

Caution: In order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.
In order to avoid cruise control cable damage, position the cable out of the way while you remove or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable. You must replace a damaged cable.

132. Install the accelerator control cable to the throttle lever.





133. Install the cruise control cable to the throttle lever.





134. Connect the fuel line to the fuel rail.
135. Connect the vapor line to the fuel vapor purge valve.





136. Install the inlet and outlet heater hoses to the water pump.





137. Install the condenser tube to the condenser.





138. Install the air conditioning condenser tube nut.
- Tighten the air conditioning condenser tube nut to 16 Nm (12 ft. lbs.).
139. Install the upper oil cooler line to the radiator.
- Tighten the lower oil cooler line fitting to 27 Nm (20 ft. lbs.).





140. Install the A/C compressor and condenser hose bolt at the accumulator.
- Tighten the A/C compressor and condenser hose bolt to 16 Nm (12 ft. lbs.).
141. Install the shift control closeout boot, if equipped with a manual transmission.
142. Install the lower radiator (outlet) hose.
143. Install the upper radiator (inlet) hose.
144. Install the fan shroud.





145. Connect the positive battery cable.
- Tighten the positive battery cable fitting to 15 Nm (11 ft. lbs.).
146. Connect the negative battery cable.
147. Recharge the A/C system.
148. Fill the crankcase with the proper quantity and grade of engine oil.
149. Disable the ignition system.
150. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
151. Enable the ignition system.
152. Start the engine and listen for unusual noises.
153. Check the vehicles oil pressure gage and confirm that the engine has acceptable oil pressure.
154. Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.
155. Listen for sticking lifters and other unusual noises.
156. Inspect for fuel, oil and/or coolant leaks while the engine is running.
157. Perform the Crankshaft Position (CKP) system variation learn procedure.
158. Bleed the brake system.
159. Bleed the power steering system.
160. Bleed the clutch hydraulic system, if equipped.
161. Perform a final inspection for the proper engine oil and coolant levels.