Engine Assembly

ENGINE ASSEMBLY





1. Connect engine lift chain (1) to engine.
2. Slowly lower engine assembly in to position.





3. Position right mount bracket (2) and install bolts (3).
4. Install mounting bolts at the right engine mount bolts and tighten bolts to 118 Nm (87 ft. lbs.).
5. Install through bolt (4) and tighten to 118 Nm (87 ft. lbs.).





6. Install A/C compressor mounting bracket (2).
7. Install A/C compressor (1) and connect lines.
8. Install exhaust manifold and upper lower heat shields Exhaust Manifold - Installation.
9. Install oxygen sensor and connect electrical connector.





10. Install Ground strap (1) near right strut tower.
11. Raise vehicle.





12. Install crankshaft position sensor (CKP) (2).
13. Connect CKP electrical connector (2).





14. Install manifold to exhaust pipe bolts (1) and tighten bolts.
15. Install generator.





16. Install lower bell housing bolts (2) and tighten.
17. Align torque converter and flex plate mark. Install torque converter bolts (1) and tighten.





18. Install inspection cover (1).





19. Install new oil filter (1).
20. Lower vehicle.
21. Install upper idler pulley.
22. Install power steering pump.





23. Install power steering line support bracket (1).
24. Install power steering pump.
25. Install accessory drive belt.
26. Connect electrical connectors at block ground, starter, A/C compressor, knock sensor, oil pressure sensor, generator, coolant temperature sensor at block, and block heater.





27. Install intake manifold and tighten bolts to 24 Nm (18 ft. lbs.) as shown.





28. Install throttle body support bracket (1).
29. Connect manifold flow control valve and electronic throttle control electrical connectors.
30. Insert wiring harness retainer into intake manifold (2).
31. Install engine oil dip stick.





32. Install PCV hose (5).
33. Install vacuum lines at throttle body and intake manifold.
34. Install intake air tube on throttle body.
35. Connect engine harness electrical connectors.





36. Install coolant hoses at coolant adapter (3).





37. Install coolant reservoir (1) and connect hose.





38. Connect fuel line to fuel rail (3).





39. Connect negative battery cable (1).





40. Install air cleaner housing (1) and connect inlet air hose.
41. Fill with coolant.
42. Fill with oil.

CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage.

43. Evacuate the refrigerant system (REFER TO HEATING AND AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE) Refrigerant System Evacuate.
44. Charge the refrigerant system (REFER TO HEATING AND AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE) Refrigerant System Charge.





45. Start engine and check for leaks.
46. Install engine cover (1).