Engine - Installation
INSTALLATION - ENGINE ASSEMBLY
1. Install transmission and power transfer unit (PTU) (if equipped), onto engine assembly.
2. Mount engine assembly onto cradle assembly.
3. Carefully position the engine cradle assembly under the vehicle.
CAUTION: While slowly lowering the body to the cradle assembly, constantly check to assure proper positioning and no damage occurs to other components or harnesses until union is made.
4. Lower the vehicle until the union is made between the cradle assembly and body, taking care to align the cradle to body marks.
5. Install the cradle supporting bolts and tighten to 163 Nm (120 lbs. ft.).
6. Install upper engine mount, tighten bolt to timing cover to 54 Nm (40 lbs. ft.). Tighten bolt to right rail 68 Nm (50 lbs.ft.).
7. Slowly raise the vehicle off of the engine cradle support.
8. Align front steering knuckles with struts and install bolts. Tighten bolts to 244 Nm (180 lbs. ft.). Front Steering Knuckle - Installation.
9. Install front wheel speed sensor wire support brackets to the struts. Tighten bolts to 12 Nm (105 lbs. in.).
10. Connect both front wheel speed sensors to wiring harness.
11. Install brake line support bracket to cradle. Tighten bolts to 12 Nm (105 lbs. in.).
12. Connect sway bar links to front struts.
13. Raise vehicle.
14. Install the steering column coupler pin.
15. Connect the engine block heater (if equipped).
16. Connect negative battery cable to transmission.
17. Route engine wiring harness connector to PCM and connect.
18. Install inner fender wells.
19. Connect both front driving lights to the front fascia.
20. Install front fascia.
21. Install engine mount nuts and tighten to 101 Nm (75 lbs.ft.).
22. Install flex plate to torque converter bolts. Tighten bolts to 75 Nm (55 lbs.ft.).
23. Install transmission inspection shield. Tighten bolts to 12 Nm (105 lbs. in.).
24. Properly align and install the drive shaft Propeller Shaft - Installation
25. Install exhaust system.
26. Connect exhaust manifold and catalytic converter oxygen sensor electrical connectors.
27. Connect starter wiring and properly position harness wiring.
28. Install front wheels.
29. Lower the vehicle.
30. Connect both front brake lines to the brake system H.C.U. and tighten.
31. Connect the ignition harness connector at the intake manifold.
32. Connect the engine wiring harness and the ground wire on left frame rail
33. Connect transmission cooler lines to transmission.
34. Connect transmission shift cable.
35. Connect transmission solenoid pack, input and output sensors and transmission range sensor.
36. Install the power brake booster and fuel vapor vacuum hoses to the engine.
37. Connect ETC connector to throttle body.
38. Connect electrical connectors to generator.
39. Connect oil pressure sending unit wiring harness connector.
40. Connect A/C electrical connector.
41. Connect suction/discharge hose at air conditioning compressor.
42. Connect lower radiator hose to engine.
43. Connect heater hoses to heater core.
44. Connect coolant reservoir hose to thermostat housing.
45. Connect the fuel line to the fuel rail.
46. Install cooling fan assemblyRadiator Fan - Installation.
47. Install radiator core support.
48. Install radiator close out panel.
49. Connect upper radiator hose.
50. Install air cleaner housing.
51. Install the engine cover.
52. Install new oil filter. Fill engine crankcase with proper oil to correct level.
53. Connect negative battery cable to battery.
54. Fill the cooling system.
55. Bleed brakes.
56. Start engine and run until operating temperature is reached and radiator fans cycle.
57. Evacuate and recharge air conditioning.
58. Check all fluid levels and properly fill.
59. Check front end alignment.