Installation

Installation Procedure





1. Remove the engine from the engine stand.
2. Slowly install the engine into the engine compartment aligning the engine mounts with the brackets.
3. When the engine mounts are aligned, install the engine mounts, putting the mount up through the engine mount brackets before inserting into the chassis mount brackets.

Notice: Refer to Fastener Notice in Service Precautions.

4. Lower the engine onto the mounts and install the upper engine mount nuts.
^ Tighten the nuts to 70 Nm (51 ft. lbs.).
5. Remove the engine hoist.
6. Lay the radiator into the radiator support, but do not install the radiator completely.





7. Raise the vehicle.
8. Install all of the lower bell housing bolts, excluding the top four.
9. Remove the two through bolts securing the transmission support.
10. Lower the transmission.
11. Install the top four bell housing bolts.
^ Tighten all eleven bell housing bolts to 50 Nm (37 ft. lbs.).
12. Raise the transmission.
13. Install the transmission support.
14. Install the 3 torque converter bolts.
^ Tighten the torque converter bolts to 60 Nm (44 ft. lbs.).
15. Install the torque converter bolt cover.
16. Install the fuel tank shield, if removed.
17. Install the engine protection shield.
18. Install the propeller shaft to the front axle pinion yoke.
19. Connect the exhaust pipe to the manifold and secure the pipe with the bolts.
^ Tighten the exhaust pipe bolts to 50 Nm (37 ft. lbs.).
20. Connect the oil level switch electrical connector.
21. Connect the oil pressure sensor electrical connector.
22. Install the oil pan drain plug.
^ Tighten the plug to 26 Nm (19 ft. lbs.).





23. Install the lower radiator hose (1).
24. Install the left and right wheel drive shafts.
25. Lower the vehicle.





26. Install the 4 grounds on the left side of the block (1).
27. Install the camshaft sensor electrical connectors.
28. Install the crankshaft sensor electrical connector.
29. Install the knock sensor electrical connector.





30. Install the generator electrical connector and battery lead (1).
^ Tighten the generator battery lead nut to 9 Nm (80 inch lbs.).
31. Install the A/C pressure sensor and clutch electrical connector.





32. Install starter electrical connectors and battery lead (1).
^ Tighten the starter battery lead to 9 Nm (80 inch lbs.).
33. Install the fuel lines at the fuel pressure regulator.





34. Install the engine harness bracket and bolt.
^ Tighten the engine harness bracket bolt to 50 Nm (37 ft. lbs.).
35. Install the front differential vent hose, to the engine harness bracket.
36. Install all the harnesses to the engine harness bracket.
37. Install the PCM.
38. Install the power brake hose at booster.





39. Install the harness retainer to the original location.
40. Install the ignition coil harness electrical connectors.





41. Clip the transmission cooler lines to the right side of the engine block.
42. Connect the camshaft phase actuator valve electrical connector.
43. Connect the front axle actuator electrical connector.
44. Connect the A/C line at the accumulator.
45. Install the oxygen sensor electrical connector.





46. Remove the lift hook J 44220.





47. Install the AIR adapter and secure the adapter with the studs.
^ Tighten the AIR adapter studs to 25 Nm (18 ft. lbs.).





48. Install the transmission filler tube bracket to AIR adapter stud and secure the bracket with the nut.
^ Tighten Torque nut to 10 Nm (89 inch lbs.).
49. Install the heater hoses to the heater core.
50. Install the power steering pump.





51. Install the power steering pump bolts. Tighten
^ Tighten the bolts to 25 Nm (18 ft. lbs.).
52. Install the drive belt.
53. Install cooling fan and shroud, tilting the radiator forward for clearance.
54. Finish installing the radiator.
55. Install transmission cooler lines together.
56. Install map Sensor.
57. Install the throttle body.
58. Install the hood latch.
59. Install the head lamp housing.
60. Install the grill.
61. Install the air intake baffle.
62. Install the washer solvent container.
63. Install the air cleaner assembly.
64. Connect the negative battery cable.
65. Install the hood.
66. Service the engine oil.
67. Fill the cooling system.
68. Recharge the refrigerant.
69. Perform the CKP system variation learn procedure.

Important: After an overhaul, the engine should be tested. Use the following procedure after the engine is installed in the vehicle.
^ Disable the ignition system.
^ Crank the engine several times. Listen for unusual noises or evidence that parts are binding.
^ Enable the ignition system.
^ Start the engine and listen for unusual noises.
^ Check the vehicle oil pressure gage or light and confirm that the engine has acceptable oil pressure.
^ Run the engine speed at about 1000 RPM until the engine has reached normal operating temperature.
^ Listen for a sucking lifter and other unusual noises.
^ Inspect for fuel, oil and/or coolant leaks while the engine is running.
^ Perform a final inspection for the proper engine oil and coolant levels.

70. Install the hood.