Installation
Engine 4.4LService Repair No - 12.41.01.99
Special Service Tools
Special Service Tools (Part 1):
Special Service Tools (Part 2):
Special Service Tools (Part 3):
Special Service Tools (Part 4):
Special Service Tools (Part 5):
Special Service Tools (Part 6):
Special Service Tools (Part 7):
Special Service Tools (Part 8):
Installation (Steps 1-32)
CAUTION: Make sure the O ring seal remains in its fitted position.
1. Install the front differential.
^ Align the dowel and tighten the bolts to 115 Nm (85 ft. lbs.)
2. Attach the transmission fluid lines to the engine.
^ Secure with the clip
3. Lower the engine onto its mounts
^ Tighten the engine mount bolts to 100 Nm (74 ft. lbs.)
4. Install the LH engine mount heat shield
CAUTION: Support the engine on a jack. The angle may need to be adjusted during this procedure
5. Lift the engine and sub frame into position
^ Connect the lifting chainss
^ Raise the engine
^ Using a suitable hydraulic jack, support the rear of the front sub frame
^ With assistance, position and secure the sub frame
^ Tighten the 6 subframe bolts
^ Step 1: Tighten to 165 Nm (122 ft. lbs.)
^ Atep 2: Turn a further 90 degrees
^ Tighten the two front subframe bolts
^ Tighten the nuts to 140 Nm (103 ft. lbs.)
6. Install the transmission
NOTE: LH illustrated, RH similar
7. Install the stabilizer bar heat shields
8. Connect the steering gear electrical connector
9. Attach the lower steering column
^ Make sure that the steering gear tag is aligned correctly, as shown
^ Install a new Torx bolt and tighten to 24 Nm (18 ft. lbs.)
NOTE: LH illustrated, RH similar
10. Connect the height sensor electrical connector
^ Align the wiring harness and secure with a cable tie
11. Install the RH driveshaft.
12. Install the LH driveshaft.
13. Fill the front differential case with the correct amount of fluid
14. Install the oil filter housing
^ Clean the component mating faces
^ Install a new O-ring seal
^ Tighten the bolts to 20 Nm (15 ft. lbs.)
15. Connect the EOP sensor electrical connector
16. Connect the engine oil temperature sensor electrical connector
17. Connect the power steering pump high-pressure line
^ Clean the component mating faces
^ Install new sealing washers
^ Tighten the union to 25 Nm (18 ft. lbs.)
18. Connect the power steering supply hose to the steering pump
^ Clean the component mating faces
^ Secure with the clip
19.Secure the PAS pipe.
20. Remove the special tools
21. Connect the engine ground cable
^ Tighten the bolt to 25 Nm (18 ft. lbs.)
22. Connect the coolant manifold hoses
^ Secure with the clips
23. Install the transmission fluid cooler
24. Connect the coolant expansion tank hose
^ Secure with the clip
25. Install the brake vacuum pump bracket
^ Attach the wiring harness clip
^ Attach the refrigerant line clip
^ Tighten the bolts to 10 Nm (7 ft. lbs.)
26. Install the brake vacuum pump
^ Tighten the nuts to 5 Nm (4 ft. lbs.)
^ Connect the vacuum line
^ Connect the electrical connector
27. Secure the engine wiring harness
^ Install the grommet
^ Connect the electrical connectors
28. Install the ECM cover
^ Tighten the Torx screws
29. Attach the purge valve assembly
^ Tighten the bolt to 45 Nm (33 ft. lbs.)
^ Connect the electrical connector
^ Connect the quick release connector
30. Connect the brake booster vacuum hose
^ Connect the quick release connector
31. Connect the fuel line to the fuel rail
^ Clean the component mating faces
^ Secure with the clip
32. Install the throttle body gasket
33. Install the EGR valve
^ Install a new gasket
^ Tighten the bolts to 10 Nm (7 ft. lbs.)
34.Connect the heater coolant hoses
^ Remove the hose clamps
35. Connect the battery positive cable to the junction box
^ Tighten the nut to 25 Nm (18 ft. lbs.)
^ Close the cover
36. Connect the battery positive cable to the battery component side wall
^ Tighten the nut to 25 Nm (18 ft. lbs.)
^ Install the cover
CAUTION: Lubricate the new seals with clean refrigerant oil
37. Connect the A/C compressor low pressure line
^ Clean the component mating faces
^ Install the new O-ring seals
^ Tighten the bolts to 10 Nm (7 ft. lbs.)
38.Connect the battery ground cable
39. Install the RH air cleaner assembly
40. Fill with engine oil
41. Fill with coolant
42. Recharge the A/C system
43. Install the engine cover
44. Carry out a complete vehicle geometry check and adjustment(alignment).