Installation

Engine









1. Position the engine in the vehicle.

2. Remove the floor crane and the jack supporting the transmission.

3. NOTE: Align the engine-to-transmission dowels before installing the engine-to-transmission bolts.

Position the shifter cable support bracket and install the 2 transmission-to-engine bolts.

- Tighten to 60 Nm (44 lb-ft).






4. Install the RH lower transmission-to-engine bolt.
- Tighten to 60 Nm (44 lb-ft).






5. NOTE: RH shown, LH similar.

Install the 4 engine support insulator-to-support insulator bracket nuts.

- Tighten to 90 Nm (66 lb-ft).






6. Position the shift cable mounting bracket, install the 2 bolts and connect the shift cable.
- Tighten to 25 Nm (18 lb-ft).






7. Install 4 new torque converter nuts.
- Rotate the crankshaft to access all of the torque converter nuts.

- Tighten to 35 Nm (26 lb-ft).






8. Install the cylinder block opening cover.





9. Position the flexplate inspection cover and install the 2 bolts.
- Tighten to 34 Nm (25 lb-ft).






10. If equipped, install the A/C compressor and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).






11. Connect the A/C compressor electrical connector and the wiring harness retainer.





12. Connect the Crankshaft Position (CKP) sensor electrical connector.





13. Position the exhaust Y-pipe and install the 4 nuts.
- Tighten to 40 Nm (30 lb-ft).






14. NOTICE: The oil cooler must be replaced or severe damage to the engine can occur.

NOTE: Make sure the tab on the oil filter adapter nests into the notch in the oil cooler.

Position a new oil cooler on the oil filter adapter and install the threaded insert.
- Tighten to 58 Nm (43 lb-ft).






15. Install a new oil filter.
- Tighten to 16 Nm (142 lb-in).






16. Connect the 2 oil cooler coolant hoses.





17. Position the power steering pump and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).






18. Using the Teflon Seal Installer Set, install a new Teflon(R) seal on the power steering pressure tube.





19. Connect the Power Steering Pressure (PSP) tube and the power steering reservoir hose to the power steering pump.
- Tighten to 20 Nm (177 lb-in).






20. Connect the lower radiator coolant hose to the oil filter adapter coolant inlet.





21. Position the fuel tube support bracket and install the 4 upper transmission-to-engine bolts.
- Tighten to 60 Nm (44 lb-ft).






22. Position the ground strap, install the bolt and connect the RH HO2S (Heated Oxygen Sensor) electrical connector and retainer.
- Tighten to 10 Nm (89 lb-in).






23. Connect the LH Heated Oxygen Sensor (HO2S) sensor electrical connector and retainer.





24. Position the transmission wiring harness and connect the transmission wiring harness retainer.





25. Connect the LH HO2S (Heated Oxygen Sensor) sensor electrical wiring harness retainer to the rear of the LH cylinder head.





26. Connect the transmission wiring harness retainers to the engine wiring harness.





27. NOTE: Do not reuse the O-ring seals. Lubricate the new O-ring seals with clean engine coolant before installing the heater outlet tube.

Insert the heater outlet tube over the new seals.






28. Connect the coolant hose to the heater outlet tube and install the heater outlet tube stud.
- Tighten to 25 Nm (18 lb-ft).






29. Position the transmission cooler tube support bracket and the starter wiring harness support bracket and install the nut.
- Tighten to 10 Nm (89 lb-in).






30. Connect the oil fill tube to the RH valve cover.





31. Install the engine oil filler tube support strap bolt.
- Tighten to 9 Nm (80 lb-in).






32. Position the engine wiring harness support bracket, install the ground cable and nut, and connect the electrical connector to the bracket.
- Tighten to 10 Nm (89 lb-in).






33. Position the generator wiring harness and connect the 2 generator wiring harness retainers.





34. Connect the engine wiring harness retainer and the 2 PCM electrical connectors.





35. Connect the electrical connector.





36. Position the crankcase ventilation tube and connect the quick connect coupling.





37. Position the generator and install the bolts.
- Tighten to 25 Nm (18 lb-ft).






38. Connect the generator electrical connections.
1. Tighten the B+ terminal nut to 8 Nm (71 lb-in).

2. Connect the S electrical connector.

3. Connect the ASI electrical connector.






39. NOTE: LH shown, RH similar.

Position the lower radiator support and install the 12 bolts.

- Tighten to 20 Nm (177 lb-in).






40. Position the wiring harness and connect the 4 wiring harness retainers.





41. Connect the 2 headlamp wiring harness retainers and position the ground cable and install the bolt.
- Tighten to 10 Nm (89 lb-in).






42. NOTE: RH shown, LH similar.

Position the upper radiator support and install the 8 bolts.

- Tighten to 20 Nm (177 lb-in).






43. NOTE: RH shown, LH similar.

Position the 2 upper radiator support plates and install the 4 bolts.

- Tighten to 20 Nm (177 lb-in).






44. NOTE: RH shown, LH similar.

Position the RH and LH air deflectors and install the pin-type retainers.






45. Position the transmission fluid cooler and install the bolt.
- Tighten to 10 Nm (89 lb-in).






46. Connect the transmission fluid cooler hose retainers.





47. Connect the horn electrical connector.





48. Connect the front impact severity sensor electrical connector.





49. If equipped, connect the air temperature sensor electrical connector.





50. Route the battery feed wiring harness to the Power Distribution Box (PDB) and insert the routing clips.





51. NOTE: Cover removed from art for clarity.

Install the battery feed cable to the PDB (Power Distribution Box) and the nuts.

- Tighten to 8 Nm (71 lb-in).






52. Position the power steering reservoir and install the 3 bolts.
- Tighten to 20 Nm (177 lb-in).






53. Position the hood latch.
1. Install the 2 bolts.

2. Connect the cable position retainer.
- Tighten to 12 Nm (106 lb-in).







54. NOTE: RH shown, LH similar.

If equipped, position the A/C condenser core in the vehicle.

1. Install the 2 bolts.

2. Install A/C condenser bracket.

3. Position the A/C condenser core.
- Tighten to 12 Nm (106 lb-in).







55. If equipped, connect the compressor discharge tube and the condenser-to-evaporator tube to the A/C condenser core and install the nuts.
- Tighten to 15 Nm (133 lb-in).






56. If equipped, connect the compressor suction tube and install the nut.
- Tighten to 15 Nm (133 lb-in).






57. If equipped, connect the A/C pressure cutoff switch electrical connector.





58. Position the radiator in the vehicle.





59. NOTE: LH shown, RH similar.

Position the radiator support brackets and install the 4 bolts.

- Tighten to 20 Nm (177 lb-in).






60. Position the fan shroud and the fan and fan clutch in the vehicle, and install the 2 bolts.
- Tighten to 6 Nm (53 lb-in).






61. Connect the degas bottle hose and power steering hose retainers to the fan shroud.





62. NOTE: The large clutch assembly nut has a RH thread and must be rotated clockwise to install it.

Using the Fan Pulley Holding Wrench and Fan Clutch Nut Wrench, install the fan blade and the fan clutch.

- Calculate the correct torque wrench setting for the following torque.

- Tighten to 133 Nm (98 lb-ft).






63. Connect the upper radiator coolant hose and the degas bottle coolant hose to the radiator.





64. Install the radiator grille support.

65. Connect the transmission cooler tubes.





66. Connect the lower radiator hose to the radiator.
- Connect the hose.

- Connect the hose hanger.






67. Install the front bumper.

68. Install the starter.

69. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

Install the intake manifold. For additional information, refer to Intake Manifold Removal and Replacement.

70. Fill the engine with clean engine oil.

71. Check the transmission fluid level and top off the fluid level as necessary.

72. Fill and bleed the power steering system.

73. If the engine was disassembled, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.

74. Start the engine and check for leaks. Stop the engine and recheck the fluid levels.

75. If equipped, evacuate and recharge the air conditioning system.