Engine - Installation

INSTALLATION

Special Tools:











NOTE: Do not use air tools to install Engine Lift Fixture (1) and Adapter Eagle (2).

1. Install the engine lift fixture (1) and adapter Eagle (2).
2. Position the engine in the engine compartment.





3. Lower and align the engine (1) with the transmission (3).
4. Install two transmission bell housing to engine block mounting bolts (2) finger tight.





5. Lower the engine assembly until the engine mount through bolts (3) line up in the frame brackets (1).
6. Raise and support the vehicle on a hoist.





7. Install the remaining transmission bell housing to engine block mounting bolts (2) and tighten to 68 Nm (50 ft. lbs.)





8. Install both the left and right side oil pan to transmission bolts (1) and tighten bolts to 54 Nm (40 ft. lbs.).
9. Connect the transmission oil cooler lines at the oil pan and tighten bolts to 12 Nm (9 ft. lbs.).





10. Install the engine mount through bolts (3) and nuts and tighten to 95 Nm (70 ft. lbs.).





11. Install all torque converter-to-driveplate bolts (1) by hand, verify the torque converter is pulled flush to the driveplate and tighten bolts to 31 Nm (23 ft. lbs.).






CAUTION: The structural dust cover must be installed as described in the Structural Dust Cover installation procedure. Failure to do so will cause severe damage to the cover.

12. Install the structural dust cover (1) Structural Dust Cover - Installation





13. Install the starter (1) and connect the starter wires Starter - Installation





14. Install the front exhaust pipe/catalytic converter assembly (4) to the exhaust manifold flange and tighten the bolts and nuts (3) to 26 Nm (19 ft. lbs.).
15. Lower the vehicle.





16. Remove the engine lift fixture and adapter Eagle (1,2).





17. Install the oil control valve and securely tighten fastener (1).
18. Connect the oil control valve (OCV) electrical connector (2).
19. Install the intake manifold Intake Manifold - Removal
20. Connect the fuel supply line Service and Repair





21. Install the three power steering pump mounting bolts through the access holes in the pulley (1) and tighten bolts to 28 Nm (21 ft. lbs.).





22. Connect the heater hoses (2) and the lower radiator hose (1).





23. Install the generator (2) and electrical connections Generator - Installation





24. Install the A/C compressor (3) A/C Compressor - Installation





25. Connect the refrigerant lines (1,3) to the A/C compressor (4) and tighten the nuts (2) to 20 Nm (15 ft. lbs.).
26. Install the viscous fan drive assembly Viscous Radiator Fan Clutch - Installation






CAUTION: Do not let the tensioner arm snap back to the freearm position, severe damage may occur to the tensioner.

27. Insert a suitable square drive ratchet into the square hole on the belt tensioner arm (7).
28. Rotate the tensioner (7) counter-clockwise and install the accessory drive belt (4).
29. Install the radiator and A/C condenser as an assembly Engine Cooling Radiator - Installation and A/C Condenser - Installation
30. Position the shroud in the radiator tank clips and Install the fan shroud mounting bolts.
31. Connect the radiator upper hose.





32. Position the upper radiator seal and install the two plastic rivets (2).
33. Install the four push pins (1).
34. Install the washer bottle.





35. Install the engine cover (1) Installation
36. Install the air cleaner housing (4).
37. Install the clean air hose (2).
38. Connect the intake air temperature (IAT) sensor electrical connector (3).





39. Fill the engine with oil
40. Fill the cooling system Service and Repair
41. Connect the negative battery cable (1).
42. Start the engine and check for leaks.
43. Evacuate and Charge the refrigerant system Refrigerant System Charge