Engine - Installation
INSTALLATION
Special Tools:
NOTE: If installing a replacement engine, transfer components such as engine mount brackets, block heater, accessories, heater hoses and tubes to the replacement engine.
1. If required, transfer the following components onto the replacement engine:
- Left exhaust down pipe
- Right exhaust down pipe
- Left engine mount bracket
- Left engine mount
- Right engine mount bracket
- Right engine mount
- Accessory drive belt tensioner
- Upper intake manifold support bracket
- Block heater (if equipped)
2. If required, remove the upper intake manifold Intake Manifold - Removal.
3. Remove the left intake manifold support bracket retaining bolts (2) and remove the support brackets (1).
4. Install the Driver Side Engine Lifting Bracket (1) on the left cylinder head with bolts (2) provided with the Engine Lifting Bracket and tighten bolts to 21 Nm (15 ft. lbs.).
5. Install the Passenger Side Engine Lifting Bracket (1) on the right cylinder head with bolts (2) provided with the Engine Lifting Bracket and tighten bolts to 21 Nm (15 ft. lbs.).
6. Position a load-leveling lifting sling (2), such as OTC(R) 4305 Engine Load Leveler or equivalent, between the engine lifting brackets (3) and an engine hoist (1).
7. Reposition the starter wire harness and the main wire harness to the rear of the engine compartment.
NOTE: Left engine mount shown, right engine mount similar.
8. Carefully lower the engine into the engine compartment while aligning the two locator dowels into the transmission housing.
9. Align the engine mounts, install both left and right engine mount lower retaining bolts (2) and tighten to 68 Nm (50 ft. lbs.).
10. Position both left and right engine mount heat shields (4), install the retaining nuts (3) and tighten to 12 Nm (9 ft. lbs.).
11. Position the electric vacuum pump (3), install the two transmission to engine retaining bolts (2) and tighten to 55 Nm (41 ft. lbs.).
12. Install the quick connect vacuum hose (2) to the electric vacuum pump (3).
13. Connect the electrical connector (1) to the electric vacuum pump (3).
14. Secure the harness retainer (4) to the mounting bracket.
15. Remove the engine lifting brackets and position the left upper intake manifold support brackets (1) and install the retaining studs (2) finger tight.
16. Route the main wire harness and starter wire harness on the engine.
17. Secure the two starter wire harness retainers (1) to the upper intake manifold support brackets.
18. Secure the main wire harness retainer (3) to the left cylinder head cover and two retainers (2) to the upper intake manifold support brackets.
19. Connect the Engine Coolant Temperature (ECT) sensor connector (3).
20. Connect the left Camshaft Position (CMP) sensor (5).
21. Secure the main wire harness retainer (2) to the cylinder head cover and one main wire harness retainer (4) to the cylinder head cover mounting stud.
22. Secure the main wire harness retainer (1) to the rear of the lower intake manifold.
23. Secure the four main wire harness retainers (1) to the right cylinder head cover.
24. Connect the electrical connectors (2) to the variable valve timing solenoids on the right cylinder head.
25. Secure the two starter wire harness retainers (1) to the right cylinder head cover.
26. Secure the starter harness to main harness retainer (3).
27. Connect the oil pump solenoid electrical connector (2).
28. Secure the four wire harness retainers (1).
29. Install the ground strap (3) to the right engine mount bracket.
30. Remove the jack supporting the transmission.
31. Raise and support the vehicle Maintenance.
32. Install the four transmission to the engine oil pan retaining bolts (1) and tighten to 55 Nm (41 ft. lbs.).
33. Install the two rubber plugs (1) covering the rear oil seal retainer flange bolts.
34. Install the side engine to transmission retaining bolt (1) and tighten to 55 Nm (41 ft. lbs.).
35. Position the torque converter dust shield (3), install the retaining bolt (2) and tighten to 12 Nm (9 ft. lbs.).
36. Install the two upper side transmission to engine retaining bolts (1) and tighten to 55 Nm (41 ft. lbs.).
37. Connect the main harness to the engine injection/ignition harness (1) at the rear of the left cylinder head.
38. Connect the main harness to the engine oil pressure/temperature harness (2) at the rear of the left cylinder head.
39. Rotate the crankshaft in a clockwise direction and install the six torque converter bolts (1) through the starter mounting hole and tighten to 42 Nm (31 ft. lbs.).
40. Install the transmission cooling lines (2) and tighten the bolt (1) to 12 Nm (106 in. lbs.).
41. Secure the starter wire harness retainer (2) and the main wire harness retainer (1) to the engine block.
42. Install the starter Starter - Installation.
43. Connect the power cord to the engine block heater (if equipped).
44. Connect the main wire harness to the Crankshaft Position (CKP) sensor (3).
45. Secure the main wire harness retainer (1) to the engine block and one main wire harness retainer (2) to the right engine mounting bracket.
46. Position the heat shield (1) over the crankshaft position (CKP) sensor.
47. If equipped with AWD, install the front axle assembly (1) with propeller shaft, intermediate shaft, halfshafts, wheels and tires Installation.
48. If required, fill the front axle with the specified type and amount of gear lubricant.
NOTE: Left side shown, right side similar.
49. Position both left and right exhaust down pipes (1) to the catalytic converters, install the retaining nuts (2) and tighten to 30 Nm (22 ft. lbs.)
NOTE: Left side shown, right side similar.
50. Connect both left and right upstream oxygen sensor (2) electrical connectors (1) to the main wire harness.
51. Position the belly pan and install the retainers (1).
52. Lower the vehicle.
53. Install the upper intake manifold and insulator Intake Manifold - Installation.
54. Install the oil level indicator (2) with bolt (1) tightened to 12 Nm (106 in. lbs.).
55. Position the heater core inlet tube (4) and install two bolts (3) tightened to 12 Nm (106 in. lbs.).
56. Install the A/C compressor (2) A/C Compressor - Installation.
57. Position the heater core return tube (1), install the upper support bracket retaining nut (2) and tighten to 12 Nm (9 ft. lbs.).
58. Connect the heater core return hose (1).
59. Position the heater core return tube lower support bracket onto the A/C lower retaining stud, install the retaining nut (1) and tighten to 12 Nm (9 ft. lbs.).
60. Install the lower heater core return hose (1) to the engine coolant pump housing.
61. Install the lower radiator hose (2) to the engine coolant pump housing.
62. Install the upper radiator hose (1) to the engine thermostat housing.
63. Connect the electrical connectors (2) to the left variable valve timing solenoids.
64. Secure the two starter wire harness retainers (1) to the left cylinder head cover.
65. Connect the A/C compressor electrical connector (1) and secure the wire harness retainer (2) to the A/C compressor discharge line.
66. Install the generator (1) Generator - Installation.
67. Rotate the accessory drive belt tensioner (7) counterclockwise until it contacts the stop and install the accessory drive belt (3), then slowly rotate the tensioner into position.
68. Install the cooling fan module Cooling Fan - Installation.
69. Connect the fuel supply hose (1) to the underbody fuel tube (2) Service and Repair.
70. Connect the fresh air makeup hose (2) to the rear of the intake manifold (1).
71. Connect the electrical connector to the right Camshaft Position Sensor (CMP) (6).
72. Secure the main wire harness retainer to the right cylinder head cover mounting stud.
73. Connect the electrical connector to the Electronic Throttle Control (ETC) (5).
74. Connect the electrical connector to the Manifold Absolute Pressure (MAP) Sensor (4).
75. Connect the brake booster vacuum hose (3).
76. Connect the PCV hose to the PCV valve (1) and to the intake manifold (2).
77. Position the EVAP purge solenoid (1) vacuum line (4) and connect the vacuum line to the intake manifold.
78. Connect the other end of the vacuum line (3) to the EVAP purge solenoid (1).
79. Position the coolant bottle (3) into the engine compartment.
80. Install the coolant bottle retaining bolts (2) and tighten to 12 Nm (9 ft. lbs.).
81. Connect the heater core purge hose (1) to the coolant bottle.
82. Connect the coolant bottle return hose (1).
83. Position the air cleaner housing (3) into the vehicle.
84. Install the air cleaner housing retaining bolt (2) and tighten to 12 Nm (9 ft. lbs.).
85. Connect the fresh air makeup hose (1) to the air cleaner housing.
86. Position the air inlet hose assembly (5) onto the throttle body and the air cleaner housing.
87. Secure the air inlet hose assembly retaining grommet onto the ball stud (4).
88. Tighten the clamp at the air cleaner housing (3) to 5 Nm (44 in. lbs.).
89. Tighten the clamp (2) at the throttle body to 5 Nm (44 in. lbs.).
90. Connect the Inlet Air Temperature (IAT) sensor electrical connector (1).
91. Install the strut tower support (6).
92. Install the cowl panel cover (2)Cowl Panel Cover - Installation.
93. Install the hood Hood - Installation.
94. If removed, install the oil filter and fill the engine crankcase with the specified type and amount of engine oil .
95. Fill the cooling system with the specified type and amount of engine coolant Service and Repair.
96. Perform the Refrigerant System Charge procedure Refrigerant System Charge.
97. Position the engine cover (1) and secure the retaining grommets onto the ball studs.
98. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.).
99. Run the engine until it reaches normal operating temperature and check for leaks.
NOTE: The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components.