Part 2

Engine Replacement - Continued

Installation Procedure




1. Install an engine hoist to the engine.
2. Remove the engine from the engine stand.
3. Position the flywheel to the crankshaft.
4. Install the flywheel bolts finger tight.
5. Use the J 37096 in order to hold the flywheel.

Notice: Refer to Fastener Notice.

6. Tighten the flywheel bolts.

Tighten the bolts to 70 N.m (52 lb ft).




7. Install the engine to the transaxle and the frame.
8. Install the transaxle bolts and studs.

Tighten the bolts/studs to 75 N.m (55 lb ft).

9. Remove the support from the transaxle.
10. Remove the engine hoist from the engine.
11. Install the power steering pressure and return lines to the power steering pump.
12. Connect the power steering line retainer at the generator bracket.




13. Place the engine wiring harness on top of the engine and position the harness branches.
14. Install the engine harness clip to the oil pan.




15. Connect the engine harness electrical connector to the oil level sensor.




16. Install the engine harness clips (1) to the transaxle studs.




17. Install the engine harness clamp bolt to the transaxle.

Tighten the 20 N.m (15 lb ft).




18. Install the engine harness clip (1) to the stud on the transaxle.




19. Connect the engine harness electrical connector to the VSS.




20. Connect the engine harness electrical connector to the transaxle.




21. Connect the engine harness electrical connector (1) to the knock sensor.
22. Connect the engine harness electrical connector (2) to the oil pressure sensor.




23. Connect the engine harness electrical connector (1) to the CKP sensor.




24. Install the engine harness clip (1) to the strut bracket.




25. Connect the engine harness electrical connector (4) to the HO2S.
26. Connect the engine harness electrical connector (3) to the generator.
27. Install the engine harness lead (2) to the generator.
28. Install the generator terminal nut (1).

Tighten the nut to 30 N.m (22 lb ft).




29. Connect the engine harness electrical connector (3) to the fuel injector harness electrical connector.
30. Install the CPA retainer (2).
31. Connect the engine harness electrical connector (1) to the intake manifold tuning valve.




32. Install the engine harness clip (1) to the bracket.




33. Install the engine harness bracket (2) to the stud.
34. Install the engine harness bracket nut (1).




35. Connect the engine harness electrical connector to the camshaft actuator magnet.
36. Install the engine harness bolt.

Tighten the bolt to 20 N.m (15 lb ft).




37. Install the engine harness clip to the engine.




38. Install the engine harness clip (1) to the ignition coil bracket.




39. Install the engine harness clip (1) to the ignition coil bracket.




40. Connect the engine harness electrical connector (2) to the ignition coil.
41. Connect the engine harness electrical connector (1) to the MAP sensor.




42. Connect the engine harness electrical connector (2) to the throttle actuator.
43. Connect the engine harness electrical connector (1) to the EVAP purge solenoid.




44. Install the exhaust crossover pipe (2) and nuts (1).

Tighten the nuts to 25 N.m (18 lb ft).




45. Install the exhaust crossover pipe shield (2) and bolts (1).

Tighten the bolts to 10 N.m (89 lb in).




46. Install the transaxle brace and bolts.

Tighten the bolts to 43 N.m (32 lb ft).




47. Install the engine harness clips (1) to the transaxle brace.




48. Install the engine harness clips (1) to the transaxle brace.




49. Install the engine mount to frame nuts.

Tighten the nuts to 47 N.m (35 lb ft).




50. Install the torque converter bolts.
51. Use the J 37096 in order to hold the flywheel.
52. Tighten the torque converter bolts.

Tighten the bolts to 63 N.m (47 lb ft).




53. Install the torque converter covers (2, 4).
54. Install the torque converter cover bolts (1, 3).

Tighten the bolts to 10 N.m (89 lb in).




55. Install the starter motor and bolts.

Tighten the bolts to 40 N.m (30 lb ft).




56. Install the transaxle brace and bolts.

Tighten the bolts to 43 N.m (32 lb ft).




57. Install the negative battery cable to the transaxle stud.
58. Install the engine harness grounds to the studs.
59. Install the engine harness ground nuts (1, 2) to the transaxle studs.

Tighten the nuts to 25 N.m (18 lb ft).




60. If necessary perform the following steps, connect the engine harness electrical connector (3) to the starter.
61. Install the engine battery positive wire terminal (2) to the stud.
62. Install the engine battery positive wire nut (1).

Tighten the nut to 20 N.m (15 lb ft).




63. Lower the vehicle over the powertrain/frame assembly.
64. Position the frame rear straps (1, 4).
65. Install the frame rear strap bolts (2, 3).

Tighten the bolts to 50 N.m (37 lb ft).




66. Install the front and rear frame bolts (1, 2).

* Tighten the front bolts to 130 N.m (96 lb ft).
* Tighten the rear bolts to 240 N.m (177 lb ft).




67. Raise the vehicle off of the J 39580.
68. Remove the J 39580 from under the frame.




69. Connect the intermediate steering shaft to the power steering gear.
70. Install the intermediate steering shaft pinch bolt.

Tighten the bolt to 48 N.m (35 lb ft).

71. Position the intermediate steering shaft seal onto the steering gear.




72. Unsecure the wheel drive shafts from the steering knuckle/struts.
73. Install the wheel drive shafts to the transaxle.
74. Verify that the wheel drive shaft is properly engaged to the transaxle by grasping the inner tripot housing and pulling outward. Do not pull on the wheel drive shaft bar. The wheel drive shaft will remain firmly in place when properly engaged.





Important: Align the ball joint cotter pin hole parallel to the knuckle in order to ease the cotter pin installation.

75. Install the ball joints to the knuckles.
76. Install the ball joint castle nuts.

Important: DO NOT loosen the castle nut in order to align the nut to the cotter pin hole.

77. If necessary, tighten the castle nut in order to align the nut slot (1) to the cotter pin hole (2) as shown.




78. Tighten the lower ball joint castle nuts (1).

Tighten the nuts to 55 N.m (40 lb ft).

79. Install NEW lower ball joint cotter pins (2) to the ball joints.





Important: Ensure that the cotter pin ends do NOT contact the ABS wheel speed sensor, the ABS sensor connector, or the drive axle.

80. Bend the ends of the cotter pin as shown in either example.




81. Install the outer tie rod (2) to the steering knuckle (1).





Important: This is a prevailing torque type fastener. You may reuse this fastener ONLY under the following conditions:

* The fastener and its counterpart are clean and free from rust.

* The fastener develops 2 N.m (18 lb in) of torque/drag against its counterpart prior to fastener seating.

If the fastener does not meet these criteria, REPLACE the fastener.

Install the tie rod end nuts (1) at the steering knuckles.

Tighten the nuts to 30 N.m (22 lb ft) plus an additional 120 degrees using the J 45059.




83. Install the stabilizer shaft links (2) to the stabilizer shaft. (left side shown, right side similar).
84. Install the stabilizer shaft link lower nuts (3).

Tighten the nuts to 23 N.m (17 lb ft).




85. Install the engine harness clips (1, 2) to the heat shield.
86. Connect the battery cable retainers at the core support.
87. Install the engine splash shield.
88. Install the catalytic converter.




89. Position and install the A/C compressor onto the stud.
90. Install the A/C compressor front bolt and nut.

Tighten the bolt/nut to 50 N.m (37 lb ft).




91. Install the A/C compressor rear bolt.

Tighten the bolt to 50 N.m (37 lb ft).

92. Connect the engine harness electrical connectors to the A/C compressor.
93. Install the drive belt.




94. Connect the engine harness electrical connectors (1) to the left and right wheel speed sensors. (right side shown, left side similar).




95. Install the front wheels and tires.
96. Install the engine mount struts. Right Side and Engine Mount Strut Bracket Replacement - Left Side.
97. Connect the fuel feed (1) and EVAP (2) line quick connect fittings.




98. Install the brake booster vacuum hose to the upper intake manifold fitting.




99. Connect the heater inlet (2) and outlet (1) hose quick connect fittings to the inlet and outlet pipes.




100. Install the radiator outlet hose to the thermostat housing.
101. Using the J 38185, release the radiator outlet hose clamp.




102. Install the radiator inlet hose to the coolant crossover.
103. Using the J 38185, release the radiator inlet hose clamp.




104. Remove the engine harness wiring branch from on top of the engine.
105. Install the air cleaner outlet duct to the throttle body and MAF/IAT sensor.
106. Tighten the air cleaner outlet duct clamps at the throttle body and the MAF/IAT sensor.

Tighten the clamps to 2 N.m (18 lb in).

107. Connect the PCV fresh air tube quick connect fitting to the air cleaner outlet duct.
108. Connect the engine harness electrical connector to the MAF/IAT sensor.




109. Install the engine harness connector to the junction block retainer.
110. Install the underhood junction block.




111. Install the engine harness clip (1) to the A/C line.




112. Install the engine harness clip (1) to the A/C line.




113. Connect the engine harness electrical connector (6) to the ABS module.
114. Connect the engine harness electrical connector (5) to the I/P harness electrical connector (4).
115. Connect the engine harness electrical connector (3) to the I/P harness electrical connector (2).
116. Connect the engine harness electrical connector (1) to the TCM.




117. Install the ECM to the air cleaner cover.
118. Install the air cleaner cover.
119. Tighten the air cleaner cover bolts.

Tighten the bolts to 4 N.m (35 lb in).




120. Install the junction block cover.
121. Install the left side diagonal brace.
122. Install the coolant reservoir.




123. Install the coolant recovery reservoir hose (2) to the crossover.
124. Position the coolant recovery reservoir hose clamp (1) at the coolant crossover.




125. Remove the J 42640 from the underside of the steering column.
126. Install the lower radiator air baffle.
127. Connect the negative battery cable.
128. Connect the positive battery cable.
129. Connect the positive battery cable at the junction box.
130. Connect the auxiliary ground cable on the inner fender.
131. Connect the electrical connector to the sensor on the negative battery cable.
132. Fill the cooling system. Refer to Draining and Filling Cooling System (Static Fill LZ9) Draining and Filling Cooling System (Vac-N-Fill).
133. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement.
134. Perform the CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn. Service and Repair




135. Align the cover to the studs on the engine, push down on the cover above the stud in order to engage the cover to the studs.
136. Install the engine oil fill cap.
137. Start the engine listen for unusual noises.
138. Inspect the engine for leaks.