E. Install Engine and Transmission Assembly

1. Locate the engine and transmission assembly under the vehicle. Lower the vehicle slowly until the engine is about 12-18 inches from being fully installed. It may be necessary to move the assembly on the cradle to clear body flanges.

2. Route the power steering low pressure hose through the engine bracket.

3. Attach the power steering line bracket to the rear of the engine.

4. Connect the oxygen sensor electrical connector.

5. Lower the vehicle until the right and left mounts are aligned.

6. Install the right engine (Figure 22) and transmission (Figure 23) mount through bolts. Tighten the bolts to 45 ft-lbs (61 N.m).

7. Raise the vehicle slightly, disconnect the engine dolly and cradle and remove them from under the vehicle.

8. Connect the primary ground cable to the left end of the transmission.

9. Install the power steering reservoir.

10. Connect the engine to body ground straps.

11. Raise the vehicle on the hoist.

12. Remove the Special Tool Bracket 6973 from the cylinder block (Figure 20).

13. Install the A/C compressor. Tighten the bolts to 30 ft-lbs (41 N.m).

14. Install the rear engine block to transmission support bracket. Tighten the bolts to 80 ft-lbs (110 N.m).

15. Install the engine support module and then install the through bolt into the front engine mount (Figure 19). Do not tighten.

16. Install the lower radiator support. Tighten the bolts to 33 ft-lbs (45 N.m).

17. Install the bolts that attach the engine support module to the lower radiator support (Figure 19). Tighten the bolts to 33 ft-lbs (45 N.m).



18. Connect the power steering fluid cooler to the lower radiator support.

19. Install the bolts that attach the engine support module to the rear crossmember. Tighten the bolts to 33 ft-lbs (45 N.m).

20. Install the upper attaching bolt for the rear support strut bracket (Figure 19). Tighten the bolt to 33 ft-lbs (45 N.m).

21. Install the through bolt for the rear engine mount (Figure 19).

22. Tighten the front and rear engine mount through bolts to 45 ft-lbs (61 N.m).

23. Connect the exhaust pipe to the rear exhaust manifold. Tighten the bolts to 24 ft-lbs (32 N.m).

24. Clean the left front driveshaft assembly spline and the oil seal sealing surface on the tripod joint.

25. Lightly lubricate the oil seal sealing surface with fresh clean transmission fluid.

26. Hold the driveshaft assembly by the tripod joint and interconnecting shaft and then install the tripod joint into the transaxle side gear as far as possible by hand (Figure 18).

27. Forcefully push the tripod joint into the side gear until the snap ring is engaged with the transaxle side gear. Test that the snap ring is fully engaged by trying to remove the tripod joint from the transaxle by hand. If fully engaged, it can not be removed by hand.





28. Clean any debris or moisture from the steering knuckle where the outer CN joint will be installed (Figure 39).

29. Slide the driveshaft into the front hub (Figure 16). Then install the steering knuckle onto the lower control arm ball joint stud.

30. Install the steering knuckle to ball joint castle nut (Figure 14). Tighten the castle nut to 70 ft-lbs (95 N.m). Install a new cotter pin.

31. Install the tie rod end into the steering knuckle. Start the tie rod end to steering knuckle nut onto the stud of the tie rod end. While holding the stud, tighten the nut to 45 ft-lbs (61 N.m) (Figure 12).

32. Install the brake rotor onto the hub.

33. Install the disc brake caliper assembly on the steering knuckle (Figure 11).

34. Install the caliper guide pin bolts and tighten to 23 ft-lbs (31 N.m).





35. Install the hub nut onto the CN joint stub axle (Figure 40).

36. With the vehicle brakes applied, tighten the hub nut to 180 ft-lbs (244 N.m) (Figure 40).

37. Install the spring washer, hub nut lock and a new cotter pin on the end of the stub axle (Figure 8). Wrap the cotter pin prongs tightly around the hub nut lock.

38. Repeat Steps 24-37 to install the right front driveshaft.

39. Install the front tire and wheel assemblies. Tighten the lug nuts to 100 ft-lbs (135 N.m).
40. Install the A/C and generator drive belt. Tighten the belt tension to 80 lbs by turning the idler pulley adjusting screw (Figure 7). Tighten the idler pulley bolt to 40 ft-lbs (54 N.m) after adjusting the belt tension.

41. Install the power steering pump drive belt. Adjust the belt tension to 80 lbs by installing a 1/2 breaker bar in the adjusting bracket (Figure 6). Tighten the locking bolt on the rear of the pump to 250 in-lbs (28 N.m). Tighten the locking bolt on the front of the pump and the pivot bolt to 40 ft-lbs (54 N.m).

42. Install the right inner splash shield.

43. Lower the vehicle.

44. Connect the A/C low pressure line to the compressor. Tighten the bolts to 200 in-lbs (22 N.m).

45. Connect the vapor canister hose.

46. Connect the brake booster vacuum hose.

47. Connect the throttle body linkage.

48. Connect the heater hoses to the engine.

49. Connect the transmission shift linkage.

50. Connect the transmission cooler line to the transmission.

51. Connect the four (4) transmission electrical connectors.

52. Install the TCM and bracket assembly.

53. Connect the black and gray connectors at the front of the TCM.

54. Connect the black and gray connectors at the rear of the PCM.

55. Connect the positive battery cable.

56. Connect the PCM connector.

57. Connect the coolant overflow hose to the engine filler neck.

58. Install the air cleaner cover, inlet tube and resonator assembly. Tighten the air inlet hose clamp to 25 in-lbs (3 N.m) and the bolt securing the resonator to the intake manifold to 45 in-lbs (5 N.m) (Figure 5).

59. Slide the radiator and fan module into position. Seat the radiator lower rubber isolators into the mounting holes.

60. Connect the air conditioning condenser lines to the condenser.

61. Connect the engine block heater wire (if equipped).

62. Connect the lower radiator hose to the radiator.

63. Connect the transmission cooler hoses. Tighten the hose clamps to 22 in-lbs (2.5 N.m).

64. Connect the radiator fan motor electrical connector.

65. Connect the upper radiator hose to the filler neck.

66. Install the upper radiator crossmember (Figure 4). Tighten the bolts to 33 ft-lbs (45 N.m).

67. Connect the fuel line to the fuel rail.

68. Charge the air conditioning system (if equipped).

69. Connect the negative battery terminal.

70. Tighten the radiator draincock to 22 in-lbs (2.5 N.m).

71. Fill the cooling system with 1-1/3 gallons (5 liters) of Mopar coolant, and then finish filling the system with water.

CAUTION:
Do not spill coolant on the drive belts, generator or painted surfaces.

72. Fill the coolant reserve bottle with a 50/50 mix of coolant and water to at least the FULL HOT mark.

73. Start the engine and run it until the radiator fan comes on. Top off the coolant reserve bottle as necessary.

74. Road test the vehicle to ensure proper operation and then check for leaks.