Installation

Engine

Special Tool(s):

Material:

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 47 Nm (35 ft. lbs.).





4. Install the RH lower transmission-to-engine bolt.
^ Tighten to 47 Nm (35 ft. lbs.).





5. NOTE: RH shown, LH similar.

Install the 4 engine mount nuts.
^ Tighten to 90 Nm (66 ft. lbs.).





6. Install the shift cable to the mounting bracket and shift linkage.





7. Install 4 new torque converter nuts. Rotate the crankshaft to access all of the torque converter nuts. Tighten to 40 Nm (30 ft. lbs.).





8. Install the cylinder block opening cover.





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





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





11. Position the exhaust Y-pipe and install the 4 nuts.
^ Tighten to 40 Nm (30 ft. lbs.).





12. CAUTION: 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 ft. lbs.).





13. Install a new oil filter.
^ Tighten to 16 Nm (12 ft. lbs.).





14. Connect the 2 oil cooler coolant hoses.





15. Position the transmission fluid cooler tube support bracket and install the nut.
^ Tighten to 12 Nm (9 ft. lbs.).

16. Using the special tool, install a new Teflon seal on the power steering pressure tube.





17. Connect the power steering pressure tube and the power steering reservoir hose to the power steering pump.
^ Tighten to 20 Nm (15 ft. lbs.).





18. Install and tighten the oil drain plug.
^ Tighten to 23 Nm (17 ft. lbs.).





19. Position the fuel line and the LH heated oxygen sensor (HO2S) brackets. Install the 4 upper transmission-to-engine bolts.
^ Tighten to 47 Nm (35 ft. lbs.).





20. Connect the transmission wiring harness and the LH and RH HO2S electrical connectors. Install the transmission wiring harness connector retainer in the bracket.





21. 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.








22. Install the heater outlet tube studs.
^ Tighten to 40 Nm (30 ft. lbs.).





23. NOTE: Lubricate the O-ring seals with clean transmission fluid before installing the transmission fluid filler tube.

Position the transmission fluid filler tube in the vehicle. Connect the HO2S electrical connector.





24. Connect the hose to the heater outlet tube.





25. Install the wiring retainers in the heater outlet tube bracket.
1 Install the knock sensor (KS) electrical connector retainer.
2 Install the engine harness routing clip retainer.





26. Connect the evaporative emission (EVAP) canister purge valve electrical connector.





27. Connect the attachments to the transmission fluid filler tube and install the fluid level indicator.
1 Connect the rear heater hose hanger.
2 Install the fluid level indicator.





28. Install the engine oil filler tube support strap bolt.
^ Tighten to 10 Nm (89 inch lbs.).

29. NOTE: Windsor engine shown, Romeo engine similar.





Position the mounting bracket, install the ground strap and nut, and connect the electrical connectors to the bracket.
^ Tighten to 25 Nm (18 ft. lbs.).





30. Connect the engine wiring harness electrical connectors.





31. Connect the powertrain control module (PCM) electrical connectors.





32. Connect the engine wiring harness to the PCM bracket.





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





34. NOTE: LH shown, RH similar.

Position the lower radiator support and install the 12 bolts.
^ Tighten to 20 Nm (15 ft. lbs.).





35. Position the RH side of the headlamp dash panel junction wiring harness.
1 Connect the electrical connector.
2 Tighten the ground cable nut to 10 Nm (89 inch lbs.).
3 Connect the routing clips.





36. Position the LH side of the headlamp dash panel junction wiring harness.
1 Tighten the ground cable nut to 10 Nm (89 inch lbs.).
2 Connect the routing clips.





37. NOTE: RH shown, LH similar.

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





38. NOTE: RH shown, LH similar.

Position the upper radiator support and install the 8 bolts.
^ Tighten to 20 Nm (15 ft. lbs.).





39. Connect the horn electrical connector.





40. Connect the front impact severity sensor electrical connector.





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





42. Route the battery feed wiring harness to the power distribution box and insert the routing clips.





43. NOTE: Cover removed for clarity.

Install the battery feed cable to the power distribution box and the 2 nuts.
^ Tighten to 8 Nm (71 inch lbs.).





44. Position the power steering reservoir and install the 2 bolts.
^ Tighten to 20 Nm (15 ft. lbs.).





45. Position the hood latch.
1 Install the 2 bolts.
2 Connect the cable position retainer.
^ Tighten to 12 Nm (9 ft. lbs.).





46. 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 (9 ft. lbs.).





47. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting.

If equipped, connect the condenser core refrigerant tubes.
1 Connect the condenser-to-evaporator tube.
^ Tighten to 18 Nm (13 ft. lbs.).

2 Connect the A/C compressor discharge tube.
^ Tighten to 39 Nm (29 ft. lbs.).





48. CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting.

If equipped, connect the A/C compressor suction tube.
^ Tighten to 47 Nm (35 ft. lbs.).





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





50. Position the radiator in the vehicle.





51. NOTE: LH shown, RH similar.

Position the radiator support brackets and install the 4 bolts.
^ Tighten to 20 Nm (15 ft. lbs.).





52. Position the fan shroud and the fan and fan clutch in the vehicle, and install the 2 bolts.
^ Tighten to 6 Nm (53 inch lbs.).





53. Insert the degas hose retainer in the fan shroud.





54. Install the fan blade assembly and fan clutch.
^ Install the fan blade and the fan clutch.
^ Using the special tool, hold the coolant pump pulley.
^ Using the special tool, tighten the fan clutch nut.
^ Tighten to 133 Nm (98 ft. lbs.).





55. Connect the upper radiator coolant hose and the degas bottle coolant hose to the radiator.
56. Install the valance panel.





57. Connect the transmission cooler tubes.





58. Position the splash shield and install the pushpin retainers.





59. Connect the lower radiator hose to the radiator.
^ Connect the hose.
^ Connect the hose hanger.

60. Install the front bumper.

61. CAUTION: The oil pump must be primed prior to starting the engine.

Fill the engine with clean engine oil.
62. Install the starter. For additional information, refer to Starting System.
63. Install the intake manifold.
64. Fill the transmission with clean transmission fluid.
65. Fill and bleed the power steering system.
66. Start the engine and check for leaks. Stop the engine and recheck the fluid levels.
67. If equipped, evacuate and recharge the air conditioning system. For additional information, refer to Heating and Air Conditioning.