Installation

If clutch disc and clutch pressure plate have been removed, install.

1. Attach Rotunda Engine Lifting Sling 014-00036 or equivalent and hoist to lifting brackets at right-hand exhaust manifold and left-hand exhaust manifold. Remove engine from work stand.
2. Lower the engine carefully into the engine compartment. Make sure right-hand exhaust manifold and left-hand exhaust manifold are properly aligned with the exhaust inlet pipes.

On a vehicle with a manual transmission, start the transmission input shaft into the clutch disc. It may be necessary to adjust the position of the transmission in relation to the engine if the input shaft will not enter the clutch disc. If the engine hangs up after the transmission input shaft enters the clutch disc splines, turn the crankshaft-damper bolt slowly to rotate the crankshaft. This action will mesh the splines and allow the engine to be mated squarely.

3. Install the engine front support and nuts and washers, or through bolts attaching it to the crossmember.
4. Install the clutch housing or converter housing upper bolts, making sure that the dowels in the cylinder block engage the housing.
5. Remove the lifting sling.
6. Raise the vehicle and secure with safety stands.

Torque Converter Alignment:

7. On a vehicle with an automatic transmission, start the converter pilot into the crankshaft. Make sure torque converter rotates freely and is not bound Up
Check dimension A.
- Minimum: 10.23 mm (7/16 inch)
- Maximum: 14.43 mm (9/16 inch)

8. Install transmission.
9. Remove the jack from under the transmission.
10. Install the starter motor and connect the battery to starter relay cables.
11. Connect the exhaust inlet pipes at the right-hand exhaust manifold and left-hand exhaust manifold.
12. Lower the vehicle.
13. Install dash panel ground cables to cylinder block.
14. Connect:
a. Fuel charging wiring to HEGO sensor connector and two transmission connectors.
b. All vacuum hoses and lines to original location as marked.
c. Fuel charging wiring to engine control sensor wiring at three places on top of right valve cover.

15. Install accelerator cable. Install speed control actuator if so equipped. Install accelerator control splash shield.
16. Connect the fuel lines at the frame.





17. If EGR pressure sensor was removed, reinstall the sensor. Tighten retaining screws to 10-15 Nm (7-11 ft. lbs.).
18. Position the EGR valve to exhaust manifold tube on the EGR valve. Start the first few threads of the flare nut. Install the bolt at the exhaust manifold end and tighten to 20-30 Nm (15-22 ft. lbs.). Final-tighten flare nut to 35-65 Nm (26-47 ft. lbs.).
19. Connect the two pressure differential hoses from the EGR pressure sensor to the EGR tube.
20. Connect the dash panel ground cable at the cylinder block.
21. Connect the heater water hoses to the water pump and cylinder block.
22. Install A/C compressor mounting bracket with assembled A/C compressor and power steering pump. Install stud and three bolts. Tighten to 40.3-54.7 Nm (30-40 ft. lbs.).
23. Position the A/C hose and manifold assembly in engine compartment with hoses vented as originally with no kinks.
24. Remove all caps and plugs. Push suction hose into coupling on accumulator and liquid line into coupling on condenser.
25. Position hose assembly manifold to A/C compressor and install retaining bolt. Tighten to 25-30 Nm (18-22 ft. lbs.).
26. Evacuate and recharge air conditioning system.
27. Install generator bracket and three bolts. Tighten to 40.3-54.7 Nm (30-40 ft. lbs.).
28. Install generator (GEN) and three bolts. Tighten to 40.3-54.7 Nm (29-40 ft. lbs.). Connect generator (GEN).
29. If removed, install water pump pulley and four screws. Tighten to 21.2-28.8 Nm (16-21 ft. lbs.).
30. Install assembled fan blade and fan clutch. Tighten with Fan Clutch Holding Tool T84T-6312-C, Fan Clutch Nut Wrench T84T-6312-D and torque wrench to 40-135 Nm (30-100 ft. lbs).

NOTE: Fan clutch has left-hand threads so it must be turned counter-clockwise for installation and tightening.

31. Lift drive belt tensioner and drive belt under tensioner pulley. Release drive belt tensioner to rest pulley on drive belt.

CAUTION: Make sure that belt is properly seated on the pulleys. One revolution of the engine with an incorrectly seated belt may snap the belt cords.

32. Install fan shroud and four screws.
33. Fill and bleed the cooling system. Fill the crankcase with the proper grade and quantity of oil.

CAUTION: This engine has aluminum components and requires a special corrosion-inhibiting coolant formulation to avoid radiator damage.

34. Connect battery ground cable.

NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.

35. Operate the engine at fast idle until it reaches normal operating temperature and check all gaskets and hose connections for leaks. Adjust ignition timing and idle speed.
36. Install the air cleaner outlet tube. Install and adjust the hood.