Steps 81 - 110

Engine Replacement Cont.

81. Remove the AIR pipe and gasket.
82. Install the J41798 to the engine.
83. Remove the spark plugs.





84. Remove the engine mount nuts.
85. Using an engine hoist and the J41798 slowly raise the engine.
86. Remove the engine from the crossmember.





87. Remove the flywheel housing bolts.
88. Remove the flywheel housing from the engine block.
89. Install the engine onto an engine stand.
90. Remove the engine hoist.
91. Remove the J41798 from the engine.
92. Remove the engine mount bracket bolts.
93. Remove the engine mount brackets from the engine block.

Installation Procedure

Important: The steps in the following procedure are in a specific order. Follow these steps in this order and ignore no details.

1. Install the engine mount brackets to the engine block.

Notice: Refer to Fastener Notice in Service Precautions.





2. Install the engine mount bracket bolts.
Tighten the engine mount bracket bolts to 50 Nm (37 ft. lbs.).
3. Install the J41798 to the engine.
4. Using an engine hoist and the J41798 raise the engine slightly.
5. Remove the engine from the engine stand.
6. Install the flywheel housing to the engine block.
7. Install the flywheel housing bolts.
Tighten the flywheel housing bolts to 50 Nm (37 ft. lbs.).
8. Using an engine hoist and the J41798 lower the engine onto the crossmember.





9. Install the engine mount nuts.
Tighten the engine mount nuts to 65 Nm (48 ft. lbs.).
10. Install the spark plugs.
11. Remove the J41758 from the engine.





12. Clean the exhaust manifold AIR pipe gasket flange, if necessary.
13. Install a NEW AIR pipe gasket and the pipe.
14. Install the AIR pipe bolts.
Tighten the AIR pipe bolts to 20 Nm (15 ft. lbs.).
15. Install the A/C compressor bracket.





16. Install the generator bracket and power steering pump bracket.
17. Install the generator bracket bolts until snug.
18. Tighten the generator bracket bolts in the following order:
18.1. Inner power steering pump reservoir bracket bolt
18.2. Upper generator bracket bolt
18.3. Outer power steering pump reservoir bracket bolt
18.4. Lower generator bracket bolt.
Tighten the generator bracket bolts to 50 Nm (37 ft. lbs.).





19. Install the power steering pump (with reservoir) to the generator bracket.
20. Install the power steering pump brace.
21. Install the power steering pump bolts.
Tighten the power steering pump bolts to 25 Nm (18 ft. lbs.).





22. Using the J25033-C install the power steering pump pulley.
23. Install the power steering pump pulley hub cap, if necessary.
24. Roll the engine and crossmember underneath the vehicle.
25. Partially lower the vehicle onto the engine and crossmember.





26. Install the ground strap (6) and ground strap bolt (5) to the rear of the left cylinder head.
Tighten the ground strap bolt (5) to 32 Nm (24 ft. lbs.).
27. Route the electrical harness and connect the following electrical connectors at the rear of the engine:
- The knock sensor wire harness (1)
- The engine oil pressure sensor (2)
- The MAP sensor (3)
- The CMP sensor (4)

28. Connect the vacuum hose to the MAP sensor.





29. Clean the exhaust manifold AIR gasket flange, if necessary.
30. Install a NEW AIR pipe gasket and the pipe (with check valve) to the right exhaust manifold.
31. Install the AIR pipe bolts until snug.





32. Install the AIR pipe bracket bolt (at the rear of the cylinder head).
Tighten the AIR pipe bolts to 20 Nm (15 ft. lbs.).





33. Vehicles equipped with a manual transmission, slide the engine and crossmember rearward. Do not force the engine onto the propeller spline.
34. Position the engine to the proper height and angle in order to install the propeller input shaft.
35. Insert the propeller input shaft into the clutch driven plate hub while maintaining the proper angle, Do Not Force. Rotate the shaft slightly to bring the 2 splines into alignment, if necessary.





36. Slowly seat the flywheel housing to the driveline.
37. Install the driveline support bolts.
Tighten the driveline support bolts to 50 Nm (37 ft. lbs.).
38. Clip the clutch actuator hose to the clutch actuator hose clip.
39. Connect the master cylinder hose to the clutch actuator hose.

Important: Do not tighten the flywheel hub collar bolt at this time.





40. Vehicles equipped with an automatic transmission, slide the engine and crossmember rearward. Do not force the engine onto the propeller spline.
41. Position the engine to the proper height and angle in order to install the propeller input shaft.
42. Install the driveline support bolts.
Tighten the driveline support bolts to 50 Nm (37 ft. lbs.).
43. Hand tighten the flywheel hub collar bolt.
44. Lower the vehicle onto the crossmember and align the dowels.

Important: Use only hand tools when tightening or torquing crossmember nuts.





45. By HAND, install new crossmember nuts until snug.
Tighten the crossmember nuts to 110 Nm (81 ft. lbs.).
46. Raise and suitably support the vehicle.
47. Remove the J39580 and the J39580-500.
48. Remove the J42203 from the vehicle.





49. Route the transmission wire harness into place.
50. Install the transmission wire harness bracket bolts.
Tighten the transmission wire harness bracket bolts to 50 Nm (37 ft. lbs.).
51. Vehicles equipped with an automatic transmission, remove the previously installed M10-1.5 x 55 mm bolts from the front of the driveline support.





52. Install 2 plugs in the driveline support.
Tighten the driveline support plugs to 50 Nm (37 ft. lbs.).





53. Connect the front automatic transmission fluid cooler pipes to the rear pipes, if equipped.
Tighten the automatic transmission fluid cooler pipes to 25 Nm (18 ft. lbs.).
54. Install the automatic transmission cooler pipe clamp bolt, (at the transmission cover), if equipped.
Tighten the automatic transmission fluid cooler pipe clamp bolt, (at the transmission cover) to 2.2 Nm (22 inch lbs.).





55. Install the automatic transmission fluid cooler pipe clamp bolt, (at the oil pan), if equipped.
Tighten the automatic transmission fluid cooler pipe clamp bolt, (at the oil pan) to 12 Nm (106 inch lbs.).
56. Install the front transverse leaf spring.
57. Install the lower control arm stud to the steering knuckle.





58. Install a NEW steering knuckle nut.
58.1. Tighten the steering knuckle nut to 20 Nm (15 ft. lbs.) to seat the ball joint stud.
58.2. Torque the steering knuckle nut an additional 210 degrees using J36660-A.
58.3. Check the steering knuckle nut for a final torque of 55 Nm (41 ft. lbs.)
59. Connect the ABS electrical connector clips to the crossmember (if equipped).
60. Install the front stabilizer shaft.
61. Clip the transmission wire harness the engine wire harness (at the white tape).





62. Install the transmission wire harness clip bolts to the engine block.
62.1. Tighten the transmission wire harness clip bolt (near the harness ground) to 32 Nm (23 ft. lbs.)
62.2. Tighten the transmission wire harness clip bolt (near the oil pan) to 25 Nm (18 ft. lbs.)
63. Install the EVO electrical connector clips to the crossmember.





64. Clip the transmission wire harness to the crossmember.
65. If equipped with RTD connect the following electrical connectors:
- Position sensor pigtail
- Shock absorber damper





66. Position the ground straps (1 and 2) to the engine block.
67. Install the engine ground strap bolt.
Tighten the engine wire harness ground bolt to 32 Nm (23 ft. lbs.).
68. Connect the left HO2S electrical connector.
69. Connect the engine oil temperature sensor (3) electrical connector.





70. Install the AC compressor and condenser hose to the A/C compressor.
71. Install the A/C compressor and condenser hose bolt (at compressor).
Tighten the A/C compressor and condenser hose bolt (at compressor) to 27 Nm (20 ft. lbs.).
72. Connect the right front HO2S sensor electrical connector.





73. Connect the oil level sensor (2) electrical connector.
74. Connect the CKP sensor (1) electrical connector.
75. Install the starter motor.
76. Install the driveline close-out panel.





77. Install the driveline close-out panel bolts.
Tighten the driveline close-out panel bolts to 12 Nm (106 inch lbs.).
78. Install the catalytic converter.
79. Install the front tires and wheels.
80. Lower the vehicle.





81. Connect the AIR pump hose to the AIR pipe.





82. Install the intermediate steering shaft to the steering gear.
83. Install the intermediate steering shaft bolt.
Tighten the intermediate steering shaft bolt to 48 Nm (35 ft. lbs.).





84. Install the power brake booster vacuum hose.
85. Install the generator.





86. Connect the following electrical connectors to the engine:
- The fuel injectors (1)
- The ignition coil main harness connectors
- The EVAP solenoid (2)
- The electric throttle motor (3)
- The TP sensor
- The ECT sensor
- The A/C compressor





87. Install the heater hoses to the water pump.





88. Install the radiator hoses to the water pump.
89. Install the fuel feed hose.
90. Connect the EVAP emission canister purge hose at the fuel line.





91. Install the right fuel injection rail cover.
92. Install the accessory drive belt.
93. Install the BPMV bracket.
94. Install the radiator.
95. Recharge the A/C system.
96. Program the transmitters.
97. Bleed the clutch hydraulic system, if equipped.
98. Perform the CKP system variation learn procedure.
99. Fill the crankcase with the proper quantity and grade of engine oil.
100. Disable the ignition system.
101. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
102. Enable the ignition system.
103. Start the engine and listen for unusual noises.
104. Check the vehicle oil pressure gauge and confirm that the engine has acceptable oil pressure.
If necessary, install an oil pressure gauge and measure the engine oil pressure.
105. Run the engine speed at about 1000 RPM until the engine has reached normal operating temperature.
106. Listen for sticking lifters and other unusual noises.
107. Inspect for fuel, oil and/or other coolant leaks while the engine is running.





108. With automatic transmission vehicles perform the following steps:
108.1. Shut off the engine.
108.2. Allow engine to cool to room temperature.
108.3. Raise the vehicle.
108.4. Tighten the prop shaft hub collar bolt (1).
Tighten the propeller shaft hub collar bolt to 125 Nm (92 ft. lbs.).





109. Install the engine flywheel housing inspection plug.
110. Perform a final inspection for the proper engine oil and coolant levels.