Installation Procedure

Installation Procedure





1. Install the J 41798 to the cylinder heads.
^ Tighten the M8 bolts to 25 Nm (18 ft. lbs.).
^ Tighten the M10 bolts to 50 Nm (37 ft. lbs.).
2. Install an engine hoist to the J 41798 .
3. Remove the engine from the engine stand.
4. Set the engine down.





5. Install the rotor.





6. Install the flexplate and bolts.
^ Tighten the bolts to 100 Nm (74 ft. lbs.).





7. Install the stator.
8. Install the stator studs.
^ Tighten the studs to 16 Nm (12 ft. lbs.).
9. Install the engine to the vehicle.
10. Remove the J 21366 from the transmission.
11. Position or install the transmission fill tube while installing the engine.





12. Install the left and right engine mount to engine mount bracket bolts.
^ Tighten the bolts to 65 Nm (48 ft. lbs.).
13. Install the upper transmission stud until snug.
14. Remove the floor jack from under the transmission bellhousing.
15. Remove the engine hoist.





16. Remove the J 41798 from the engine.
17. Install the ignition coils, as required.
18. Raise the vehicle.





19. Install the transmission nuts.
^ Tighten the nuts to 12 Nm (106 inch lbs.).





20. Install the transmission studs (1) and bolts (2).
^ Tighten the studs/bolts to 50 Nm (37 ft. lbs.).





21. Install the transmission oil level indicator tube to the transmission.





22. Install the transmission oil level indicator tube bolt.
^ Tighten the bolt to 18 Nm (13 ft. lbs.).





23. Remove the J 46093 from the engine block.





Important: It is highly recommended to use a 8 mm ball end hex key to install and hand tighten the torque converter bolts. Then use a 3/8 inch, 6-point shallow thin wall socket and a wobble extension to torque the torque converter bolts in order to prevent possibly stripping the bolts.

24. Install the torque converter bolts.
^ Tighten the bolts to 63 Nm (46 ft. lbs.).





25. Install the passenger side closeout cover and bolt.
^ Tighten the bolt to 12 Nm (106 inch lbs.).





26. Install the positive battery cable clip and bolt.
^ Tighten the bolt to 9 Nm (80 inch lbs.).
27. Install the catalytic converter.





28. Install the oil pan skid plate and bolts, if equipped.
^ Tighten the bolts to 20 Nm (15 ft. lbs.).





29. Install the engine shield and bolts, if equipped.
^ Tighten the bolts to 20 Nm (15 ft. lbs.).
30. Lower the vehicle.





31. Install the vacuum brake booster hose.





32. Install the power steering pump bracket (3) and bolts (1, 2).
^ Tighten the bolts to 25 Nm (18 ft. lbs.).





33. Position the power steering pump (1) with the lines attached to the bracket.
34. Install the power steering pump bolts (2).
^ Tighten the bolts to 25 Nm (18 ft. lbs.).





35. Install the battery cable junction block bracket bolts (2) to the power steering pump bracket.
^ Tighten the bolts to 9 Nm (80 inch lbs.).
36. Install the battery cable clip bolt (1).
^ Tighten the bolt to 9 Nm (80 inch lbs.).





37. Install the power steering pump harness to the vehicle.
38. Connect the power steering pump harness electrical connector (4) to the power steering pump.
39. Install the ground bolt (3).
^ Tighten the bolt to 25 Nm (18 ft. lbs.).
40. Install the power steering pump harness clip (1) to the bracket.





41. Install the power steering pump harness clip (2) to the bracket.
42. Install the power steering pump harness bolt (3).
^ Tighten the bolt to 25 Nm (18 ft. lbs.).





43. Connect the power steering pump harness 42-volt electrical connectors (3, 5).
44. Install the power steering pump harness 42-volt connector (5) to the wheelhouse panel.





45. Connect the engine harness electrical connector (3) to the power steering pump.





46. Position the cable.
47. Install the 3-phase cable to the SGCM studs.
48. Install the 3-phase cable nuts.
^ Tighten the nuts to 9 Nm (80 inch lbs.).
49. Install the SGCM cover and bolts.
^ Tighten the bolts to 9 Nm (80 inch lbs.).





50. Install the 3-phase cable bracket cover bolt (1).
^ Tighten the bolt to 9 Nm (80 inch lbs.).





51. Install the radiator vent inlet hose to the throttle body.
52. Position the vent inlet hose clamp at the throttle body.





53. Position the upper portion of the engine wiring harness.
54. Raise the vehicle.
55. Position the lower engine wiring harness.
56. Slide the channel pin into the oil pan tab.
57. Install the battery cable channel bolt.
^ Tighten the bolt to 12 Nm (106 inch lbs.).





58. Connect the following electrical connectors to the engine:
^ The CKP sensor (1)
^ The engine oil level sensor (3)
^ The coolant heater, if equipped
59. Lower the vehicle.





60. Connect the fuel feed line.
61. Install the EVAP tube.
62. Connect the EVAP purge solenoid vent tube to the solenoid (1) and vapor pipe (2).





63. Connect the following electrical connectors:
^ The oil pressure sensor (1)
^ The CMP sensor (3)
64. Position the harness ground and engine ground strap to the block.
65. Install the harness ground bolt at the left rear of the engine block.
^ Tighten the bolt to 16 Nm (12 ft. lbs.).
66. Position the harness ground (2) and auxiliary negative battery cable, if equipped, to the block.
67. Install the harness ground bolt at the right rear of the engine block.
^ Tighten the bolt to 16 Nm (12 ft. lbs.).





68. Connect the ECT sensor (5) electrical connector.
69. Position the harness ground (2) and negative battery cable (3) to the block.
70. Install the engine wiring harness ground bolt (4).
^ Tighten the bolt to 25 Nm (18 ft. lbs.).





71. Install the harness clips (1) to the fuel rail.
72. Connect the main coil harness (4), fuel injectors (3), and ETC (2) electrical connectors on the right side.
73. Engage the CPA retainer on the ETC.
74. Install the CPA retainer (1) to the main coil harness connector.





75. Install the harness clips (3, 5) to the fuel rail.
76. Connect the main coil harness (4) and fuel injector (2) electrical connectors on the left side.
77. Install the CPA retainer (1) to the main coil harness connector.





78. Connect the MAP sensor (1) and knock sensor (2) electrical connectors.





79. Install the harness bracket nut (2).
^ Tighten the nut to 5 Nm (44 inch lbs.).
80. Connect the EVAP canister purge solenoid (1).
81. Install the auxiliary heater water pump.
82. Install the heater hoses.





83. Install the radiator outlet hose to the water pump and close the hose clamp.





84. Install the radiator inlet hose to the water pump and close the hose clamp.





85. Install the A/C compressor (2).
86. Install the A/C compressor bolts.
^ Tighten the bolts to 50 Nm (37 ft. lbs.).
87. Connect the compressor electrical connections.
88. Remove the caps from the compressor and line openings. Install NEW sealing washers.
89. Install the suction hose and bolt to the compressor.
^ Tighten the bolt to 16 Nm (12 ft. lbs.).
90. Install the discharge hose and bolt to the compressor.
^ Tighten the bolt to 16 Nm (12 ft. lbs.).
91. Install the A/C drive belt.
92. Install the radiator support.
93. Connect the ESB.





94. Remove the hood hinge bolts from the service position.
95. Lower the hood to the normal position.
96. Install the hood hinge bolts.
^ Tighten the bolt to 25 Nm (18 ft. lbs.).
97. Remove the fender covers.
98. Fill the crankcase with the proper quantity and grade of engine oil.
99. Perform the CKP system variation learn procedure.
100. Test the vehicle using the following procedure:
1. Disable the ignition system.
2. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
3. Enable the ignition system.
4. Start the engine and listen for unusual noises.
5. Check the vehicle oil pressure gage or light and confirm that the engine has acceptable oil pressure.
6. Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature.
7. Listen for sticking lifters and other unusual noises.
8. Inspect for fuel, oil, and/or coolant leaks while the engine is running.
9. Perform a final inspection for the proper engine oil and coolant levels.
101. Install the engine sight shield.
102. Close the hood.