Engine - Installation

INSTALLATION

CAUTION: Care must be taken when installing the engine to prevent pinching the power steering rack sensor with the left engine mount.










1. Connect the engine lifting bracket (2) from the Engine Support Fixture 8534B to the right rear of the cylinder head outer most bolt access hole. Tighten the bolt (5) to 21 Nm (15 ft. lbs.).
2. Install a bolt into the inner most bolt access hole next to the engine lifting bracket to assure lifting bracket positioning. Tighten the bolt (5) to 21 Nm (15 ft. lbs.).










3. Connect an engine hoisting chain (1) to the engine lifting point on the left side of the rear timing cover (2) and the previously installed 8534B engine lifting bracket.






NOTE: As the engine is lowered into the engine bay area, install and hand tighten the A/C compressor bolt (1) retaining the transmission cooler lines (2).







CAUTION: Care must be taken when installing the engine to prevent pinching the power steering rack sensor with the left engine mount. Constantly check to assure proper positioning and no damage occurs to other components or harnesses until union is made.

4. Carefully install the engine into the engine bay area and complete the union with the transmission.
5. Route the engine wiring harness behind the engine and tighten the four accessible transmission housing to engine mounting bolts (2) to 68 Nm (50 ft. lbs.).





6. Install the wire harness support bracket (1) onto the upper most transmission bolts with two nuts (2). Tighten the nuts (2) to 21 Nm (15 ft. lbs.).





7. Install the ignition capacitor (2) and tighten the mounting bolt (1) to 21 Nm (15 ft. lbs.).
8. Connect the ignition capacitor electrical connector (3).





9. Connect the electrical connector to the knock sensor.





10. Connect and lock the electrical connector to the EGR valve.





11. Connect the electrical connector to the right upstream oxygen sensor.
12. Install the ground wire (1) to the left cylinder head. Tighten the bolt (2) to 21 Nm (15 ft. lbs.).





13. Connect six electrical connectors (1) to the fuel injectors.
14. Connect and lock six electrical connectors (2) to the ignition coils.





15. Install the upper radiator hose (1).





16. Connect the electrical connector to the oil pressure switch (1).










17. Connect the electrical connector to the camshaft position sensor (1).
18. Connect the electrical connector to the coolant temperature sensor (2).





19. Install the coolant reservoir (3) and tighten the bolts (1) to 10 Nm (89 in. lbs.).
20. Install the power steering reservoir (2) to the coolant reservoir (3) and engage the lock tab.





21. Connect the electrical connector to the left upstream oxygen sensor.
22. Install the ground wires (1) and (2) to the right cylinder head. Tighten the bolt (3) to 21 Nm (15 ft. lbs.).





23. Connect the fuel supply tube (1) to the fuel rail (2) Service and Repair





24. Connect the heater hose (1) to the extension pipe (2).










25. Connect the heater hose (2) and coolant reservoir hose (3) to the rear coolant pipe (1).





26. Connect the front section of the A/C liquid line (8) to the rear section of the A/C liquid line (10) with a new dual plane seal. Install the nut (6) and tighten to 22 Nm (16 ft. lbs.).
27. Connect the front section of the A/C suction line (9) to the rear section of the A/C suction line (12) with a new dual plane seal. Install the nut (7) and tighten to 22 Nm (16 ft. lbs.).





28. Connect the discharge line (4) to the A/C compressor (5) with a new dual plane seal. Install the nut (2) and tighten to 23 Nm (17 ft. lbs.).
29. Connect the engine wire harness to the compressor clutch field coil connector (1).





30. Install the power steering pump (3) to the engine bracket (2) with three mounting bolts (1) through access holes in the pulley. Tighten the bolts to 28 Nm (21 ft. lbs.).
31. Install the accessory drive belt Serpentine Accessory Drive Belt - Installation





32. Install the upper intake manifold (1) and upper intake manifold support brackets (2) Intake Manifold - Installation.










33. Install the air cleaner body (6) Air Cleaner Body - Installation





34. Raise and support the vehicle Service and Repair.
35. Install the engine mount to cradle nuts (1) and tighten to 75 Nm (55 ft. lbs.).





36. Install the four bolts (1) securing the engine oil pan (2) to the transmission (3) and tighten to 55 Nm (40 ft. lbs.).





37. Install the two remaining engine to transmission housing mounting bolts (2) accessible from below the vehicle and tighten to 68 Nm (50 ft. lbs.).





38. Install the torque converter bolts (3):
- If equipped with the 42RLE transmission, tighten the four bolts to 75 Nm (55 ft. lbs.).
- If equipped with the NAG1 transmission, tighten the six bolts to 42 Nm (31 ft. lbs.).





39. Install the torque converter access cover (1). Tighten the bolt (2) to 12 Nm (105 in. lbs.).










40. Install the starter (1) and closeout plate (3) . Starter - Installation





41. Connect the right exhaust pipe to the exhaust manifold (1) and tighten the ball flange nuts to 34 Nm (25 ft. lbs.).
42. Connect the electrical connector to the right downstream oxygen senor (2).










43. Connect the left exhaust pipe to the exhaust manifold (2) and tighten the ball flange nuts to 34 Nm (25 ft. lbs.).
44. Connect the electrical connector (1) to the left downstream oxygen senor (3).





45. Install the crankshaft position sensorCrankshaft Position Sensor - Installation.










46. Install the ground strap (3) to the transmission mounting bolt. Tighten the nut to 21 Nm (15 ft. lbs.).
47. Attach the power cord to the engine block heater (4) (if equipped).





48. Tighten the previously installed A/C compressor mounting bolt (1) securing the transmission cooling lines (2) to 26 Nm (19 ft. lbs.).





49. Connect the heater hose (2) to the oil cooler (if equipped) or to the engine coolant tube (1).






CAUTION: Prior to coupling installation, make sure gear is centered in its travel to match clockspring centering in steering column.

50. Align the coupling (2) with the input shaft (3) and install the steering coupling. Install a new pinch bolt (1). Tighten the bolt to 54 Nm (40 ft. lbs.).





51. Connect the generator electrical connections . Generator - Installation





52. Connect the lower radiator hose (2).
53. Install a new oil filter Engine Oil Filter - Installation.
54. Install the belly pan Belly Pan - Installation.





55. Lower the vehicle.
56. Fill the cooling system to the proper level using the appropriate coolant Service and Repair.
57. Fill engine crankcase with proper oil to correct level .
58. Evacuate and recharge the air conditioning system Refrigerant System Charge.
59. Install the strut tower support (6) with four bolts. Tighten the bolts to 20 Nm (15 ft. lbs.).
60. Install the windshield cowl panel assembly (1) Cowl Panel Cover - Installation
61. Install the hood Hood - Installation.
62. Connect the negative battery cable and tighten nut to 5 Nm (45 in. lbs.).
63. Start and operate the engine until operating temperature is reached and the radiator fans cycle.

NOTE: The Cam/Crank Variation Relearn procedure must be performed anytime there has been a repair/replacement made to a powertrain system, for example: flywheel, valvetrain, camshaft and/or crankshaft sensors or components PCM/ECM Reprogramming