With Manual Transmission

WITH MANUAL TRANSMISSION

Special Tools:

NOTE: Perform the following steps to prepare a replacement engine for installation into the vehicle.

1. Install the RH engine mount bracket (1) with six bolts (2) tightened to 25 Nm (18 ft. lbs.).

NOTE: Automatic transmission equipped engine mount shown, manual transmission equipped engine mount similar.

2. Install the RH engine mount isolator (3) and support bracket (1) to the engine mount bracket with three bolts. Tighten the isolator to engine bracket bolts in the sequence shown to 60 Nm (44 ft. lbs.).

4. Install the (10299) (1) on the vacuum pump mounting surface with three bolts (2) provided with the engine lifting bracket. Tighten the bolts to 20 Nm (15 ft. lbs.).

5. Attach a load-leveling lifting sling (4), such as OTC(R) 4305 Engine Load Leveler or equivalent, between the front engine mounting bracket (3), the engine lifting bracket (2) and an engine hoist (1).

NOTE: Perform the following steps to install components on a replacement engine if required.

6. Install the accessory mounting bracket (1) with three bolts (4) and two nuts (2 and 3) tightened as follows:
- Three bolts (4) to 50 Nm (37 ft. lbs.)
- One nut (3) to 50 Nm (37 ft. lbs.)
- One nut (2) to 25 Nm (18 ft. lbs.)

7. Install the ground wire with the bolt (5) tightened to 9 Nm (80 in. lbs.).

8. Install the block heater (3) (if equipped) Engine Block Heater - Installation.

9. Install the oil level indicator tube (1). Tighten the bolt (2) to 9 Nm (80 in. lbs.).

10. Install the A/C compressor (3) with discharge line (1) and suction line (5) A/C Compressor - Installation.

11. Install the generator (3) and connect the electrical wiring Generator - Installation.

12. Install the accessory drive belt (4) Serpentine Accessory Drive Belt - Installation.

13. Install the flywheel dust cover (2). Tighten the bolt (1) to 9 Nm (80 in. lbs.).

14. Install the flywheel Installation.

15. Install the clutch pressure plate and disc Clutch Disc - Installation.

NOTE: Perform the following steps to install the transmission to the engine if required.

16. Install the transmission on the engine with the upper bell housing bolts (1) tightened to 60 Nm (44 ft. lbs.).

17. Install the nut (1) and stud (2) and tighten to 60 Nm (44 ft. lbs.).
18. Install the remaining transmission bell housing bolts (3) and tighten to 40 Nm (30 ft. lbs.).

19. Install the two bolts (1) to the flywheel dust cover and tighten to 9 Nm (80 in. lbs.).

20. Install the starter assembly (5) and connect the electrical wiring (2) Starter - Installation.

21. Position the engine and transmission in the vehicle.

NOTE: Automatic transmission equipped engine mount shown, manual transmission equipped engine mount similar.

22. Install the LH engine mount isolator (1) with three bolts (2 and 3). First tighten the isolator to engine bracket bolt (3) to 110 Nm (81 ft. lbs.) and then tighten the isolator to body bolts (2) to 50 Nm (37 ft. lbs.).

NOTE: Automatic transmission equipped engine mount shown, manual transmission equipped engine mount similar.

23. Install the RH engine mount isolator (3) and support bracket (1) to the engine mount bracket with three bolts. Tighten the isolator to engine bracket bolts in the sequence shown to 60 Nm (44 ft. lbs.).
24. Install the RH engine mount isolator (3) to the body with three bolts (2). Tighten the isolator to body bolts (2) to 60 Nm (44 ft. lbs.).

CAUTION: When servicing components near the vacuum pump, avoid contact with the plastic nipple that connects the vacuum pump to the brake booster hose. It is possible to crack the plastic nipple resulting in a brake booster vacuum leak.

CAUTION: The vacuum hose and the pressurized coolant bottle return hose have the same quick-connect fitting end. Verify that the hoses are correctly installed. Failure to properly install the hoses can result in engine damage.

25. Install the vacuum pump (1) and wiring harness bracket Vacuum Pump - Installation.
26. Connect the main wire harness connector (2) to the engine harness.

27. Connect the fuel vapor purge hose (3) to the intake manifold.
28. Connect the fuel line (2) to the fuel rail and close the hose retainer (1) Service and Repair.

29. Install the A/C suction line (1) with a new O-ring seal to the A/C expansion valve. Install the nut (2) and tighten to 20 Nm (15 ft. lbs.).
30. Connect the heater core inlet hose (4) and outlet hose (3) to the heater core.

31. Install the battery cable (1) to the battery terminal and tighten the nut (2) to 5 Nm (45 in. lbs.).

32. Connect the shift cable (1) to the lever.

33. Install the retainer (1) to the shift cable.

34. Connect the shift selector cable (1) to the lever.

35. Install the retainer (1) to the shift selector cable.

36. Install the ground strap (1) to the transmission.

37. Connect the electrical connector (1) to the reverse lamp switch.

38. Install the hydraulic clutch slave cylinder to the transmission with two bolts (1). Tighten the bolts to 20 Nm (15 ft. lbs.).

39. Install the hydraulic clutch line support bracket (2) to the transmission with two bolts (1).

40. Install the upper radiator hose (2) to the engine.
41. Install the lower radiator hose (3) to the engine.
42. Install the windshield washer fluid reservoir and engage the hose retainer (4) to the filler neck.

43. Install the pressurized coolant bottle (5) Coolant Recovery Bottle - Installation.

44. Raise and support the vehicle Maintenance.
45. Install the rear engine mount bracket (5) with two bolts (2 and 4).
46. Install the rear engine mount isolator (7) to the transmission with the rear engine mount bracket bolt (3) and nut (6) tightened to 80 Nm (59 ft. lbs.).
47. Tighten the isolator bolt (1) to 130 Nm (96 ft. lbs.).

48. Install both axle shafts Half Shaft - Installation.
49. Fill the transmission with the proper fluid to the correct level Procedures.

50. Lower the vehicle.
51. Clean the mating surfaces of the cylinder head and the maniverter flange.
52. Install a new maniverter gasket on the cylinder head.

CAUTION: The maniverter studs are installed in the cylinder head with a thread sealant. If the studs rotate during service this indicates that the seal is broken and the stud must be replaced. Failure to replace the studs can result in engine oil leaking onto the exhaust manifold.

53. Mark the end of the nine maniverter mounting studs with a paint pen or equivalent to indicate possible stud rotation.
54. Guide the maniverter (4) into place onto the studs. Install and tighten the nine nuts (1) to 20 Nm (15 ft. lbs.).
55. Check the markings on the studs for indication of rotation. If there is evidence of stud rotation, replace the stud Exhaust Manifold Stud Replacement.
56. Connect the upstream (2) and downstream (3) oxygen sensor electrical connectors.

57. Install the maniverter heat shield (2) with four bolts (3) and two nuts (1). Tighten the nuts (1) and bolts (3) to 9 Nm (80 in. lbs.).

58. Raise and support the vehicle Maintenance.
59. Install the muffler flexible intake pipe to the maniverter flange with two nuts (1). Tighten the nuts (1) to 25 Nm (18 ft. lbs.).
60. Install the maniverter pipe extension support to the oil pan. Tighten the bolt (2) to 50 Nm (37 ft. lbs.).

61. Install the front cooling module assembly (4) with four bolts (1), eight bolts and washers (2) and eight bolts and washers (3). Tighten the eight bolts (2) to 45 Nm (33 ft. lb.). Tighten the four bolts (1) to 24 Nm (18 ft. lb.). Tighten the eight bolts (3) to 45 Nm (33 ft. lb.).

62. Engage the wire harness retainer (1) to the bottom of the bumper reinforcement.

63. Engage the wire harness connector (1) to the bumper reinforcement.

64. Connect the electrical connector (2) to the horn (1).

65. Connect the electrical connector (1) to the right and left front impact sensors (3) Front.

66. Press down the latch release (3) and install the hood latch cable (2) to the latch.

67. Engage the A/C liquid line (1) to the A/C discharge line (2) and connect the lines to the A/C condenser tapping block (3) using new dual plain seals lubricated with clean refrigerant oil. Install the retaining bolt (4) and tighten to 14 Nm (10 ft. lbs.).

68. Connect the lower coolant hose to the radiator.
69. Connect the cooling fan electrical connector (3).

70. Connect the upper coolant hose to the radiator.
71. Connect the electrical connector to the cooling fan resistor (1).

72. Install the right and left headlamp units (2) Headlamp Unit - Installation.

73. Install the front fascia (1) Front Bumper Fascia - Installation.
74. Install both front inner wheel well splash shields Splash Shield - Installation.
75. Install both front tire and wheel assemblies Tires And Wheels - Installation.

76. Remove the four bolts (1) and install the tunnel support brace (2). Reinstall the four bolts (1) and tighten to 90 Nm (60 ft. lb.).

77. Install the belly pan Belly Pan - Installation.

78. Lower the vehicle.
79. Position the battery tray and PCM in the vehicle. Route the wire harness and close the wire harness retainers (3).
80. Install the ground strap (4) with nut (1) tightened to 5 Nm (44 in. lbs.).

81. Install the battery tray (3) with one nut (5) and two bolts (1) tightened to 25 Nm (18 ft. lbs.).
82. Engage the engine wire harness connector (2) to the battery tray (3).
83. Engage two engine wire harness retainers (4) to the battery tray (3).
84. Engage two starter wire harness retainers (6) to the battery tray (3).

85. Connect the Powertrain Control Module (PCM) harness connectors (1 and 2).

86. Install the oil separator housing (4) to the cylinder head cover with three bolts (2) tightened to 13 Nm (115 in. lbs.).
87. Connect the vent hose (3) to the oil filler neck.
88. Connect the PCV hose (1) to the intake manifold.

89. Install the air cleaner body (6) Air Cleaner Body - Installation.

90. If removed, install the oil filter and fill the engine crankcase with the proper oil to the correct level Service and Repair
91. Fill the transmission Procedures.
92. Fill the cooling system Service and Repair.
93. Install and connect the battery Battery - Installation.
94. Evacuate and charge the refrigerant system Refrigerant System Charge.
95. Install the engine cover (1).
96. Run the engine until it reaches normal operating temperature. Check cooling system for correct fluid level Service and Repair

NOTE: The Cam/Crank Variation Relearn procedure must be performed using the scan tool anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components PCM/ECM Reprogramming .