Engine - Installation

ENGINE ASSEMBLY





1. Position the engine/transaxle assembly under the vehicle and slowly lower the vehicle in short length spans. Inspect at each interval for potential engine or transaxle contact to vehicle components. Move the cradle/dolly fixture (2) as necessary to allow for installation clearance.





2. Continue lowering the vehicle until the right side engine mount (3) and left side transaxle mount align to their mounting locations. Install the right side engine mount bolts (1) and tighten to 50 Nm (37 ft. lbs.).





3. Install the left side transaxle mount bolts (2) and tighten to 98 Nm (72 ft. lbs.).





4. Connect the oil cooler lines to the transaxle. An audible 'click' should be heard. Verify the connection by pulling outward.
5. Position the transaxle bracket on the transaxle and install bolts (1). Finger tighten the bolts (1) at this time.
6. Remove the safety straps from the engine/transaxle assembly. Slowly raise the vehicle and remove the engine dolly and cradle.





7. Raise and support the vehicle.
8. Install the fourth transaxle bracket bolt (3) and tighten to 95 Nm (70 ft. lbs.).
9. Install the transaxle bracket to isolator through bolt (1) and tighten to 75 Nm (55 ft. lbs.).





10. Install the torque converter-to-driveplate bolts (1) and tighten to 88 Nm (65 ft. lbs.).





11. If equipped with the 62TE transmission, install the torque converter dust shield (2) and bolt (1) tightened to 6 Nm (53 in. lbs.).





12. If equipped with the 41TE transmission, install the structural collar (3) as follows:

CAUTION: The collar must be tightened using this service procedure, as damage to transaxle case and/or oil pan may occur.

- Position the structural collar (3) on the engine and transaxle.
- Install and finger tighten all bolts (1) and (2).

NOTE: Make sure that structural collar (3) is flush with the oil pan and the transmission bell housing.

- Pre-tighten the vertical collar bolts (2) to 1.1 Nm (10 in. lbs.).
- Tighten the horizontal collar bolts (1) to 55 Nm (40 ft. lbs.).
- Starting from the center and working outward, tighten the vertical collar bolts (2) to 55 Nm (40 ft. lbs.).





13. Clean the rear maniverter gasket mounting surfaces Procedures.
14. Install the rear maniverter gasket (3), rear maniverter (2) and the rear maniverter fasteners (1). Tighten the fasteners to 23 Nm (17 ft. lbs.).





15. Install the rear maniverter heat shield (3). Tighten fasteners (1 and 2) to 12 Nm (106 in. lbs.).










16. Connect the rear downstream oxygen sensor (3) to the engine wiring harness connector (5).
17. Connect the rear upstream oxygen sensor (2) to the engine wiring harness connector (1).





18. Install the intermediate shaft (4).
19. Install the intermediate shaft bolts (1) and (5). Tighten bolt (1) to 38 Nm (28 ft. lb.) and bolts (5) to 23 Nm (17 ft. lb.).
20. Install the heat shield (3) and heat shield bolts (2).





21. Install the crossunder pipe (3) to the rear maniverter with pipe fasteners (1) and (2). Hand tighten fasteners.





22. Install the exhaust extension pipe (2) to the cross under pipe with pipe fasteners (1). Hand tighten fasteners.





23. Lower the vehicle.
24. Tighten the three previously installed rear engine mount bracket bolts (1) to 95 Nm (70 ft. lbs.).





25. Install the lower EGR tube (2) Exhaust Gas Recirculation (EGR) Tube - Installation





26. Clean the front maniverter gasket mounting surfaces Procedures.
27. Install a new gasket (3), front maniverter (2) and the front exhaust maniverter attaching bolts (1). Tighten the bolts to 23 Nm (17 ft. lbs.).





28. Install the upper maniverter heat shield (2) and the heat shield fasteners (1). Tighten fasteners to 12 Nm (106 in. lbs.).





29. Connect the coolant recovery container hose (3) from the radiator to the coolant recovery container (4).
30. Install the coolant recovery container (4) with two fasteners (1). Tighten fasteners to 10 Nm (89 in. lbs.).
31. Connect the return hose (2) to the coolant recovery container (4).





32. Install the heater hose (3) to the coolant outlet connector (4).
33. Install the upper radiator hose (5) to the coolant outlet connector (4).
34. Install the power steering reservoir (2) to the strut tower bracket with the mounting screw (1). Tighten the mounting screw to 12 Nm (106 in. lbs.).





35. Raise and support the vehicle.
36. Install the generator with two upper mounting bolts. Hand tighten bolts.
37. Install the lower generator mounting bolt and tighten to 27 Nm (20 ft. lbs.).
38. Tighten the two upper generator mounting bolts to 27 Nm (20 ft. lbs.).





39. Install the A/C compressor (1) to the engine with three bolts (2). Tighten the bolts to 25 Nm (18 ft. lbs.).





40. Connect the heater return hose (1) to the pipe connection at right front frame rail area.
41. Connect the lower radiator hose (2).





42. Install the front maniverter-to-cross under pipe fasteners (1) and (2). Tighten to 27 Nm (20 ft. lb.).
43. Tighten the previously installed rear maniverter-to-cross under pipe fasteners to 29 Nm (21 ft. lb.).
44. Tighten the previously installed exhaust extension pipe to the cross under pipe fasteners to 27 Nm (20 ft. lb.).





45. Install the power steering pump and bracket assembly (1) with two pump mounting bracket bolts (2) behind the pump on the back of the engine. Do not tighten the bolts at this time.





46. Install the pump mounting bracket bolt (1) near the pump pulley.
47. Tighten all three pump mounting bracket bolts to 30 Nm (22 ft. lbs.).










48. Install the power steering belt (2) Serpentine Accessory Drive Belt - Installation.










49. Install the accessory drive belt (2) Serpentine Accessory Drive Belt - Installation.





50. Install the fore/aft cross-member (4) Crossmember - Installation





51. Install the left and right splash shields (2) Splash Shield - Installation.





52. Install both axle shafts (2) Half Shaft - Installation.





53. Install the closeout panel (1) onto the fascia (3) Front Lower Fascia Closeout - Installation.





54. Install the left and right lower frame splash shields (2).





55. Install the front tire and wheel assemblies Tires and Wheels - Installation





56. Ensure that the oil pan drain plug is tight and install a new oil filter Engine Oil Filter - Installation.
57. Install the belly pan (2), if equipped.





58. Lower the vehicle.
59. Remove the tape or plugs from the A/C discharge line (2) and jumper line (4) fittings.
60. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
61. Connect the A/C discharge line (2) to the jumper line (4).
62. Install the nut (3) that secures the A/C discharge line to the jumper line. Tighten the nut to 18 Nm (13 ft. lbs.).
63. Connect the wire harness connector (1) to the A/C pressure transducer (6).





64. Remove the tape or plugs from the compressor port and the refrigerant line fitting.
65. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the suction line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
66. Connect the A/C suction line (6) to the A/C compressor (3).
67. Install the nut (4) that secures the A/C suction line to the A/C compressor. Tighten the nut to 20 Nm (15 ft. lbs.).
68. Connect the engine wire harness (1) to the A/C compressor connector (2).





69. Install the engine oil dipstick and tube (2). Tighten bolt to 20 Nm (15 ft. lbs.).





70. Connect the generator B+ terminal and field connectors.





71. Install the cooling fan module (2) to the radiator and engage the two upper retainers.
72. Install five screws (1) retaining the wire harness to the upper core support.
73. Connect the fan motor electrical connectors (4).
74. Secure three wire harness retainers (3) and the wire harness connector (5) to the cooling fan module (2).










75. Connect the front downstream oxygen sensor (3) to the engine wiring harness connector (2).
76. Connect the front upstream oxygen sensor (5) to the engine wiring harness connector (1).





77. Connect the gearshift cable (1) to the manual valve lever (2).





78. Connect the fuel supply hose (2) to the fuel rail (1) Service and Repair.





79. Install the upper intake manifold (1) Intake Manifold - Installation.





80. Connect engine harness to main harness connectors (5) and (6).
81. Connect engine harness connector C2 (4) and transmission harness connector C4 (3) to the PCM.
82. Install the black ground cable to the remote negative battery post. Tighten the nut (2) to 16.5 Nm (145 in. lbs.).
83. Install the red starter cable to the remote positive battery post. Tighten the nut (1) to 16.5 Nm (145 in. lbs.).










84. Install the throttle body air inlet hose and air cleaner body assembly Air Cleaner Body - Installation.
85. Evacuate and recharge the Air Conditioning system Refrigerant System Charge.
86. Fill the engine crankcase with the proper oil to the correct level Service and Repair
87. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lb.).
88. Fill the cooling system Service and Repair.
89. Start the engine and run until operating temperature is reached.

NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components Programming and Relearning