Installation
Engine
All vehicles
1. NOTE: Clean the engine support insulator frame bracket-to-crossmember mating surfaces of any dirt or foreign material prior to engine installation.
With the help of an assistant and using the floor crane, position the engine in the vehicle.
Automatic transmission vehicles
2. NOTICE: The torque converter must be installed in it's original orientation to the flexplate or engine damage may occur.
Check that the flexplate is positioned so that the 2 sloted holes are shown at the 6 o'clock position and the index marks are aligned.
3. NOTE: The upper 2 transmission-to-engine bolts will be installed later.
Install the lower 5 engine-to-transmission bolts.
- Tighten to 48 Nm (35 lb-ft).
All vehicles
4. NOTICE: The engine support insulator through bolts and transmission support insulator nuts can not be tightened until the support insulators are supporting the full weight of the engine and transmission assembly, or damage to the vehicle or engine support insulator may occur.
Remove the the floor crane.
5. NOTICE: Only use hand tools when installing the engine support insulator through bolt or damage to the engine support insulator-to-cylinder block bracket can occur.
NOTICE: The engine support insulator through bolts must be discarded and new bolts installed or damage to the vehicle may occur. They are a tighten-to-yield design and cannot be reused.
Install a new LH engine support insulator through bolt finger tight.
6. NOTICE: The engine support insulator through bolt must be discarded and a new bolt installed, or damage to the vehicle or engine support insulator may occur.
NOTICE: Only use hand tools when installing the engine support through bolt or damage to the engine support insulator may occur.
Install a new LH engine support insulator through bolt.
- Tighten to 350 Nm (258 lb-ft).
7. NOTICE: Only use hand tools when installing the engine support insulator through bolt or damage to the engine support insulator-to-cylinder block bracket can occur.
NOTICE: The engine support insulator through bolts must be discarded and new bolts installed or damage to the vehicle may occur. They are a tighten-to-yield design and cannot be reused.
Tighten the new LH engine support insulator through bolt.
- Tighten to 350 Nm (258 lb-ft).
Automatic transmission vehicles
8. Install the 4 new torque converter-to-flexplate nuts.
- Tighten to 35 Nm (26 lb-ft).
9. Install the cylinder block opening cover.
10. Install the flexplate inspection cover and the 2 bolts.
11. NOTICE: The transmission support insulator-to-crossmember nuts must be discarded and new nuts installed, or damage to the vehicle or transmission support insulator may occur.
NOTE: The transmission support insulator studs may come out of the insulator while removing the nuts. Install new transmission support insulator studs if the studs come out of the insulator.
Remove and discard the 2 transmission transmission support insulator nuts. Install 2 new transmission transmission support insulator nuts.
- Tighten to 115 Nm (85 lb-ft).
- If required, install new transmission support insulator stud(s) (W790019) and tighten to 75 Nm (55 lb-ft).
12. NOTE: LH shown, RH similar.
Install the 4 exhaust manifold flange nuts.
- Tighten to 40 Nm (30 lb-ft).
13. Connect the 2 Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) electrical connectors.
All vehicles
14. Position the oil cooler and install the threaded shaft.
- Tighten to 58 Nm (43 lb-ft).
15. Connect the 2 oil cooler coolant hoses.
16. Install a new engine oil filter.
17. Attach the starter motor wiring harness pin-type retainer to the oil pan.
18. Install the starter.
19. Remove the Engine Lifting Brackets.
Automatic transmission vehicles
20. Install the 2 upper engine-to-transmission bolts.
- Tighten to 48 Nm (35 lb-ft).
21. Install the transmission fluid indicator tube and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
22. Install the transmission fluid indicator.
All vehicles
23. Connect the lower radiator hose to the block and install the clip.
24. Position the power steering pump and install the 3 bolts.
25. Install the power steering pump pressure line and the bolt.
- Tighten to 25 Nm (18 lb-ft).
26. Using the Power Steering Pump Pulley Installer, install the power steering pump pulley.
27. Install the transmission cooler lines and starter motor wiring harness brackets and nut.
- Tighten to 25 Nm (18 lb-ft).
28. Install the A/C compressor and 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
29. Attach the wiring harness pin-type retainer to the RH valve cover.
30. Install the ground strap and bolt to the bulk head.
- Tighten to 10 Nm (89 lb-in).
31. Connect the engine harness electrical connector and attach the pin-type retainer to the battery case.
32. Connect the PCM electrical connector and attach the wiring harness retainer.
33. Connect the A/C compressor electrical connector attach wiring harness retainer to A/C compressor stud bolt.
34. Attach the generator wiring harness pin-type retainer.
35. Using the Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, install the cooling fan.
Manual transmission vehicles
36. Install the clutch and pressure plate.
All vehicles
37. Install the cooling module.
38. 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 Service and Repair.
39. Rotate the accessory drive belt tensioner clockwise and install the accessory drive belt.
40. NOTE: Align the index marks made during hood removal.
Position the hood and install the 4 bolts.
- Tighten to 12 Nm (106 lb-in).
41. Fill the crankcase with clean engine oil.
42. Evacuate and charge the A/C system.
43. Fill and bleed the power steering system.
44. If the engine was disassembled, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.