ENGINE INSTALLATION[AJ (3.0L Duratec)]

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1.  Assemble two SSTs using the bolt (M6) and nut, then install them in the position shown in the figure for the cylinder head (RH).

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2.  Install with the transaxle on the crossmember.

3.  Install the five bolts to the transaxle.

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4.  Position the joints haft bracket and install the bolts.

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5.  Install a new gasket and the RH exhaust manifold.

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6.  Install the generator.

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7.  Connect the EGR pipe and the HO2S connector.

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8.  Connect the OSS sensor connector.

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9.  Connect the KS connector.

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10.  Install the starter.

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11.  Install the bolt and connect the transaxle harness to the bracket.

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12.  Connect the transaxle harness.

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13.  Connect the TR switch.

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14.  Connect the HO2S sensors.

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Caution

•  If the SSTs installed to the cylinder head (RH) interfere with the brake pipe, the brake pipe could be damaged. Do not allow the SSTs to interfere with the brake pipe.

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15.  Using the SST, position the engine and transaxle on a suitable lift.

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16.  Install the engine and transaxle in the vehicle.

17.  Install the four bolts to the engine mount member.

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18.  Install the two front crossmember nuts.

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19.  Install the two front crossmember bolts.

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20.  Position the No.4 engine mount rubber and install the bolts.

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Note

•  The next two steps must be carried out with the vehicle raised and the engine and transaxle supported by the lift.

21.  Install No.3 engine mount bracket, bolts and nuts.

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22.  Remove the lift.

23.  Install the four bolts.

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24.  Install the four torque converter mounting nuts.

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25.  Install the access cover.

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26.  Connect the two transaxle cooler lines.

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27.  Install the cooler line bracket bolt.

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28.  Install the bolt between the steering shaft and steering gear.

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29.  Connect the LH and RH struts to the steering knuckles and install the bolts.

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30.  Install the brake calipers to the steering knuckle.

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31.  Position the LH and RH ABS sensors and install the bolts.

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32.  Connect the LH and RH stabilizer control link to the shock absorber.

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33.  Connect the LH and RH tie-rod ends to the steering knuckle.

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34.  Connect the LH and RH ball joints.

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35.  Install the propeller shaft. (See PROPELLER SHAFT REMOVAL/INSTALLATION.)

36.  Install both front wheel and tire assemblies. (See WHEEL AND TIRE REMOVAL/INSTALLATION.)

37.  Install the A/C compressor.

38.  Install the catalytic converter. (See CATALYTIC CONVERTER REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)

39.  Install the front tube. (See FRONT PIPE REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)

40.  Install the lower splash shield.

41.  Install the power steering pressure hose bracket.

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42.  Lower the vehicle.

43.  Install the dipstick.

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44.  Connect the power steering pressure line.

•  Install the bracket bolt.

•  Connect the PSP switch connector.

•  Connect the power steering pressure line.

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45.  Connect the power steering return line.

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46.  Connect the heater hoses.

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47.  Connect the vacuum line.

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48.  Connect the brake vacuum hose.

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49.  Connect the selector cable.

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50.  Install the cables and the nuts.

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51.  Install the BJB cover.

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52.  Connect the connector to the BJB.

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53.  Position the thermostat housing and connect the five hoses.

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54.  Connect the PCM connector.

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55.  Connect the purge solenoid valve outlet tube.

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56.  Connect the accelerator cable.

57.  Connect the fuel line. (See BEFORE SERVICE PRECAUTION[AJ (3.0L Duratec)].)

58.  Install the air cleaner outlet tube and air cleaner. (See AIR CLEANER REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)

59.  Install the battery and the battery tray. (See BATTERY REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)

60.  Install the water pump drive belt. (See DRIVE BELT REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)

61.  Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT[AJ (3.0L Duratec)].)

62.  Refill the crankcase with oil. (See ENGINE OIL REPLACEMENT[AJ (3.0L Duratec)].)

63.  Start the engine, and inspect and adjust the following:

•  Runout and contact of the pulley and belt

•  Leakage of engine oil, engine coolant, ATF and fuel

•  Ignition timing, idle speed, and idle mixture (CO and HC concentration) (See ENGINE TUNE-UP[AJ (3.0L Duratec)].)

•  Engine-driven accessories operation

Note

•  If there is any malfunction, loosen the engine mount installation bolts and nuts, and adjust the engine installation position.

•  If installing an overhauled engine, perform a road test and verify that there is no abnormal vibration or noise.