Installation

Engine








Installation

1. WARNING: Before servicing a vehicle equipped with a fire suppression system, depower the system by following the procedure in Fire Suppression System. Failure to follow the instructions may result in serious personal injury.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
2. Using the special tool, install the engine assembly in the vehicle.





3. NOTE: When vehicle is raised, verify that the torque converter is correctly seated.

Install the 4 bolts and 1 stud.
^ Tighten to 34 Nm (25 ft. lbs.).





4. Attach the wiring harness to the retainers on the transmission.
5. Connect the output shaft speed sensor, transmission range sensor and the turbine shaft speed sensor electrical connectors.





6. Connect the heated oxygen sensor (HO2S) and the solenoid body sensor electrical sensors.





7. Raise the transmission and install the transmission insulator.
8. Install the 2 insulator bolts.
^ Tighten to 90 Nm (66 ft. lbs.).





9. Lower the transmission and install the 2 transmission insulator nuts.
^ Tighten to 30 Nm (22 ft. lbs.).





10. NOTE: LH shown, RH similar.

Install the 2 engine mount nuts.
^ Tighten to 90 Nm (66 ft. lbs.).





11. Using the special tool, install the LH HO2S.
^ Tighten to 41 Nm (30 ft. lbs.).





12. Connect the LH HO2S electrical connector.





13. Install the 4 torque converter nuts.
^ Rotate the crankshaft to access the nuts.
^ Tighten to 36 Nm (27 ft. lbs.).





14. Install the rubber access plug.





15. Install the inspection cover and the 3 bolts.
^ Tighten to 19 Nm (14 ft. lbs.).





16. Install the starter motor and install the upper and lower starter bolts finger-tight.
^ Tighten the upper bolt to 25 Nm (18 ft. lbs.).
^ Tighten the lower bolt to 25 Nm (18 ft. lbs.).





17. Connect the starter electrical connections and install the nuts.
^ Tighten the B-terminal nut to 12 Nm (9 ft. lbs.).
^ Tighten the S-terminal nut to 6 Nm (53 inch lbs.).
^ Install the solenoid terminal cover.





18. Position the exhaust, install the 4 new nuts and remove the support.
^ Tighten to 48 Nm (35 ft. lbs.).





19. Install the power steering pump and the 3 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





20. Install the A/C compressor and the 3 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).





21. Connect the A/C compressor electrical connector.





22. Connect the engine wiring harness retainers to the A/C compressor.





23. Connect the crankshaft position (CKP) sensor electrical connector.





24. Position the transmission oil cooler tubes and install the bolt.
^ Tighten to 15 Nm (11 ft. lbs.).





25. Install the transmission cooler tube support bracket.
^ Tighten to 10 Nm (89 inch lbs.).





26. Install the power steering tube bracket.
^ Tighten to 10 Nm (89 inch lbs.).





27. CAUTION: The oil cooler must be replaced or severe damage to the engine can occur.

If equipped, install a new oil cooler and oil cooler hoses.
28. Connect the power steering pressure (PSP) switch electrical connector.





29. Connect the power steering electrical connector.





30. If equipped, connect the block heater electrical connector.
31. Connect the engine oil pressure (EOP) switch electrical connector.





32. Install the 2 top bellhousing bolts.
^ Tighten to 48 Nm (35 ft. lbs.).





33. Install the cooling fan.

34. NOTE: Do not reuse hose clamps. Use appropriately sized worm-style clamps in place of the constant tension clamps.

Connect the lower radiator hose.





35. Connect the upper radiator hose to the hose connection.





36. Connect the PCM electrical connectors.





37. Position the ground strap and install the bolt.
^ Tighten to 10 Nm (89 inch lbs.).





38. NOTE: Do not reuse hose clamps. Use appropriately sized worm-style clamps in place of the constant tension clamps.

Connect the heater hoses.





39. Connect the A/C low charge protection switch electrical connector.





40. Connect the A/C electrical connector.





41. Install the ground strap.
^ Tighten to 10 Nm (89 inch lbs.).





42. Attach the pin-type retainer and install the generator battery cable and nut.
^ Tighten to 9 Nm (80 inch lbs.).





43. Attach the generator battery cable retainer to the RH valve cover stud bolt.





44. Connect the fuel tube spring lock coupling.
45. Connect the 2 hoses and the canister purge valve electrical connection.





46. Connect the vacuum hose.





47. Install the air cleaner and outlet pipe.
48. Install the accessory drive belt.
49. Install the support bracket and the 2 nuts.
^ Tighten to 10 Nm (89 inch lbs.).





50. Install the wiper mounting arm and pivot shaft.
51. Fill the crankcase with clean engine oil.
52. Connect both battery cables. For additional information, refer to Battery.
53. Fill and bleed the cooling system.
54. Install the hood.

55. WARNING: If the vehicle is equipped with a fire suppression system, repower the system. For important safety warnings and procedures, refer to Fire Suppression System. Failure to follow these instructions may result in serious personal injury.

If equipped with fire suppression system, repower the system.