Engine - Installation

INSTALLATION






NOTE: Do not use air tools to install Engine Lift Fixture and Adapter 8984A (2,3).

1. Install the engine lift fixture 8984A (2) and adapter 8984-UPD (4).
2. Using a suitable engine hoist, lower the engine into in the engine compartment.
3. Automatic transmission equipped vehicles, align the engine with the transmission.
4. Install two transmission to engine block mounting bolts finger tight.
5. Lower the engine assembly until the engine mount studs rest in the frame brackets and remove the engine hoist.





6. Manual transmission equipped vehicles, install the transmission.
7. Raise and support the vehicle.





8. Install the transmission (3) to oil pan (2) bolts (1) and tighten to 39 Nm (29 ft. lbs.).





9. Install the remaining transmission (3) to engine block (1) mounting bolts (2) and tighten to 68 Nm (50 ft. lbs.).





10. Install and tighten the front engine mount retaining nuts to 95 Nm (70 ft. lbs.).






CAUTION: It is essential that the correct length bolts are used to attach the converter to the flexplate. Bolts that are too long will damage the clutch surface inside the torque converter.

11. Automatic transmission equipped vehicles, rotate the crankshaft in clockwise direction and install all torque converter to flexplate bolts (1) finger tight.
12. Verify that the torque converter is pulled flush to the flexplate and tighten bolts to 88 Nm (65 ft. lbs.).





13. Install the inspection cover (1) and tighten bolt (2) to 11 Nm (8 ft. lbs.).





14. Position the starter motor into the transmission.
15. Connect the solenoid wire to the starter motor (snaps on).
16. Position the battery cable to the solenoid stud, install the battery cable eyelet nut and tighten to 11 Nm (8 ft. lbs.).
17. Install the three starter motor retaining bolts (2) and tighten to 54 Nm (40 ft. lbs.).
18. Install the starter (1) heat shield (4) and securely tighten nuts (3).





19. Install the exhaust pipes (4) to the manifolds and connect the oxygen sensor electrical connectors (2) Catalytic Converter - Installation.





20. Connect the right and left knock sensor (1) electrical connectors (5).






NOTE: The Crankshaft Position (CKP) sensor is located at the right-rear side of the engine block.

21. Connect the CKP sensor electrical connector (1).
22. Connect the oil temperature sensor electrical connector.
23. Connect the oil pressure sensor electrical connector.
24. Connect the transmission oil cooler lines to their retainers at the oil pan.










25. Install the lower radiator hose (1).





26. Install the belly pan (2).
27. Lower the vehicle.





28. Remove the engine lift fixture 8984A (2) and adapter 8984-UPD (4).
29. Install the left coolant tube.
30. Install the left and right side wiring harness.





31. Connect the camshaft position sensor electrical connector (4).





32. Connect the heater hoses (1,2).
33. Connect the ground wires to the rear of each cylinder head.





34. Install the three power steering pump (1) retaining bolts (2) through the access holes in the pulley and tighten the bolts to 28 Nm (21 ft. lbs.).





35. Install the intake manifold Intake Manifold - Installation.





36. Connect the fuel line (1) to the fuel rail Service and Repair.





37. Install the generator (2) and connect the electrical connectors . Generator - Installation





38. Install the A/C compressor (3) .





39. Install the engine mount heat shield (1) and tighten fastener (2).





40. Position the front section of the A/C suction line (2) into the engine compartment.
41. Remove the tape or plugs from the fittings that connect the front section of the A/C suction line to the rear section of the A/C suction line (3).
42. Lubricate a new dual plane seal with clean refrigerant oil and install it onto the suction line fitting. Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
43. Connect the front section of the A/C suction line to the rear section of the A/C suction line.
44. Install the nut (1) that secures the front section of the A/C suction line to the rear section of the A/C suction line and tighten the nut to 22 Nm (16 ft. lbs.).





45. Position the front section of the A/C liquid line into the engine compartment.
46. Remove the tape or plugs from the fittings that connect the front section of the A/C liquid line to the rear section of the A/C liquid line (3).
47. Lubricate a new dual plane seal with clean refrigerant oil and install it onto the liquid line fitting. Use only the specified seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
48. Connect the front section of the A/C liquid line to the rear section of the A/C liquid line.
49. Install the nut (1) that secures the front section of the A/C liquid line to the rear section of the A/C liquid line and tighten the nut to 22 Nm (16 ft. lbs.).






NOTE: The Manifold Absolute Pressure (MAP) sensor (3) is mounted into the top rear of the intake manifold near the cowl hood seal (1).

50. Connect the MAP sensor electrical connector and slide the release lock into position.





51. Connect the coolant temperature sensor (3) electrical connector (2).





52. Connect all ignition coil electrical connectors (1).
53. Connect all fuel injector electrical connectors.






NOTE: The ignition capacitor (2) is attached to the left rear corner of the intake manifold (3).

54. Connect the ignition capacitor (2) electrical connector (1).






CAUTION: Do not let the tensioner arm snap back to the freearm position, sever damage may occur to the tensioner.

55. Rotate the accessory drive belt tensioner (7) counterclockwise until it contacts it's stop and install the accessory drive belt (4) onto the pulleys, then slowly release the tensioner.
56. Install the cooling fan Cooling Fan - Installation.










57. Install the upper radiator hose (2).





58. Install the strut tower support (6) and tighten bolts to 38 Nm (28 ft. lbs.).
59. Install the cowl top panel Cowl Panel Cover - Installation.





60. Install the air cleaner housing (1) and clean air tube (2) Air Cleaner Body - Installation.
61. Install the make up air hose.
62. Connect the intake air temperature (IAT) sensor connector.
63. Fill the engine with oil .
64. Fill the cooling system Service and Repair.





65. Snap the engine covers (1) onto the fuel rails.





66. Connect the negative battery cable (3).
67. Charge the A/C system Refrigerant System Charge
68. Start the engine and check for leaks.
69. Road test the vehicle.