Engine - Installation

INSTALLATION - ENGINE ASSEMBLY





1. Attach special tool #8342A engine lifting fixture (1).
a. Attach special tool #8342A to the front of the left cylinder head (2).
b. Attach special tool #8342A to the rear of the right cylinder head (3).
2. Lower engine into engine compartment.
3. Remove special tool #8342A (1).

CAUTION: Do not tighten the transmission case to engine block bolts until all bolts have been hand started, and the two mating surfaces are completely joined together, as damage to cylinder block or transmission could occur.

4. Install bell housing to cylinder block bolts and tighten to 68 Nm (50 ft. lbs.).
5. Install EGR valve and tube assemblyEGR Valve - Installation.




6. Connect coil, injector (2), capacitor, and knock sensor connectors.
7. Connect the fuel line (1).
8. Install upper intake manifoldIntake Manifold - Installation.




9. Install purge solenoid (5).
10. Connect all ground straps.
11. Connect all vacuum lines and electrical connectors.




12. Raise vehicle.
13. Align flexplate and torque converter.

NOTE: Make sure all four bolts are installed finger tight before torqueing bolts.

14. Tighten torque converter bolts to 75 Nm (55 ft. lbs.).
15. Using a block of wood and a suitable lifting device under the oil pan, raise the engine.
16. Install the structural collar (3) and position in place.

NOTE: Make sure that structural collar (3) is flush with the oil pan (1) and the transmission bell housing.

17. Finger tighten all bolts (2) & (4).
18. Tighten the structural collar to oil pan bolts (2) to 55 Nm (40 ft. lbs.).
19. Tighten structural collar to transmission bolts (4) to 55 Nm (40 ft. lbs.).




20. Install the power steering pump (3).
21. Install the A/C compressor (4)A/C Compressor - Installation.




22. Install the crankshaft position sensor and connect electrical connectorCrankshaft Position Sensor - Installation.
23. Connect oil pressure sensor (1) electrical connector.




24. Install starter (2), tighten bolts to 41 Nm (30 ft. lbs.)
25. Connect electrical connectors at starter.




26. Connect the coolant pipe (1) to coolant hose.
27. Connect the exhaust pipes to the manifolds.
28. Connect the down stream oxygen sensor connectors.
29. Connect A/C compressor electrical connectors.




30. Install new oil filter (3).




31. Install lower splash shield (2) and tighten retaining bolts (1).
32. Lower vehicle.




33. Install power steering pump (3)Power Steering Pump - Installation.
34. Connect lines to power steering pump (3).
35. Install accessory drive belt (5)Accessory Drive Belt - Installation.




36. Install air cleaner housing assembly (3)Air Cleaner Housing - Installation.
37. Connect intake air temperature sensor connector.




38. Connect negative battery (1) cable.




39. Fill coolant systemService and Repair.
40. Fill engine with correct grade of oil (5).
41. Install strut tower support (2).
42. Install cowl screen (1).
43. Install wiper armsWiper Arms - Installation.
44. Install the hood.




45. Fill and bleed power steering system.
46. Evacuate and charge A/C systemRefrigerant System Charge.Refrigerant System Charge.
47. Start engine and check for leaks.