Installation Procedure (Part 1 of 2)

Installation Procedure

^ Tools Required
- J 36660 Torque Angle Meter

1. Install engine lifting devise and remove engine from the stand.

Notice: Refer to Fastener Notice in Service Precautions.





2. For the manual transmission, install the flywheel (2) and flywheel bolts (1).
^ Tighten the flywheel bolts (1) to 15 Nm (11 ft. lbs.). Use the J 36660 to torque the flywheel bolts an additional 50 degrees.





3. For the automatic transmission, install the flywheel (2) and flywheel bolts (1).
^ Tighten the flywheel bolts (1) to 15 Nm (11 ft. lbs.). Use J 36660 to torque the flywheel bolts an additional 50 degrees.





4. For the manual transmission, install the clutch disc (6) and pressure plate (2) to the flywheel (5).
5. Install the pressure plate bolts (1).
^ Tighten the pressure plate bolts (1) to 20 Nm (15 ft. lbs.). Use J 36660 to torque the pressure plate bolts (1) an additional 45 degrees.
6. Align the flywheel housing to the engine.





7. For the manual transmission, install the flywheel housing to engine bolts (1, 2) and nuts (3).
^ Tighten the flywheel housing to engine bolts (1, 2) and nuts (3) to 95 Nm (70 ft. lbs.).
8. If equipped with a automatic transmission remove the J 21366 from the transmission.





9. For the automatic transmission, install the transmission to engine bolts and nut.
^ Tighten the transmission to engine bolts and nut to 95 Nm (70 ft. lbs.).
10. Connect the electrical connectors to the transmission.
11. If equipped with the manual transmission install the following:





12. Left side transmission support (1).
13. Left side transmission support brace bolts (2, 3). Tighten
^ Tighten the left side transmission support brace bolts (2) to 50 Nm (37 ft. lbs.).
^ Tighten the left side transmission support brace bolts (3) to 28 Nm (21 ft. lbs.).





14. Right side transmission support (1).
15. Right side transmission support brace bolts (3, 4).
^ Tighten the right side transmission support brace bolts (3, 4) to 50 Nm (37 ft. lbs.).
16. If equipped with the automatic transmission install the following:





17. Install the torque converter to flywheel bolts.
^ Tighten the torque converter to flywheel bolts to 63 Nm (47 ft. lbs.).





18. Install the torque converter cover (2).
19. Left side transmission support (4).
20. Left side transmission support bolts (3, 5).
21. Left side transmission support nut (1). Tighten
^ Tighten the left side transmission support bolts (3) to 8.5 Nm (75 inch lbs.).
^ Tighten the left side transmission support bolts (5) to 28 Nm (21 ft. lbs.).
^ Tighten the left side transmission support nut (1) to 80 Nm (59 ft. lbs.).





22. Right side transmission support (4).
23. Right side transmission support brace bolts (1, 2, 3).
24. Right side transmission support nut (6).
^ Tighten the right side transmission support brace bolts (1) to 8.5 Nm (75 inch lbs.).
^ Tighten the right side transmission support bolts (2, 3) to 50 Nm (37 ft. lbs.).
^ Tighten the right side transmission support nut (6) to 80 Nm (59 ft. lbs.).
25. With the aide of an assistant, lower the engine and transmission to the crossmember.





26. Install the left engine mount bracket (1) and mount bracket stud (2).
27. Install the left engine mount bracket bolts (3).
^ Tighten the left engine mount bracket bolt (3) to 100 Nm (74 ft. lbs.).
^ Tighten the left engine mount bracket stud (2) to 87 Nm (64 ft. lbs.).





28. Install the right engine mount bracket (3) and the engine mount bracket bolts (1, 2).
^ Tighten the two right engine mount bracket bolts (1) to 100 Nm (74 ft. lbs.).
^ Tighten the right engine mount bracket bolt (2) to 50 Nm (37 ft. lbs.).
29. Remove the lifting devise from the engine.





30. Install the generator to the engine.
31. Install the positive cable nut to the generator terminal.
^ Tighten the positive cable nut to generator terminal to 22 Nm (16 ft. lbs.).





32. Connect the generator electrical connector.
33. Install the power steering pump.





34. Install the power steering pump nuts (3).
^ Tighten the power steering nuts (3) to 30 Nm (22 ft. lbs.).





35. Install the drive belt tensioner.
36. Install the drive belt tensioner bolts.
^ Tighten the drive belt tensioner bolts to 50 Nm (37 ft. lbs.).





37. Install the A/C compressor.
38. Install the A/C compressor bolts.
^ Tighten the A/C compressor bolts to 50 Nm (37 ft. lbs.).
39. Install the A/C compressor rear bracket.





40. Install the A/C compressor rear bracket stud (1).
41. Install the A/C compressor rear bolts (2, 3).
^ Tighten the A/C compressor rear bracket stud (1) to 50 Nm (37 ft. lbs.).
^ Tighten the A/C compressor rear bolts (2, 3) to 30 Nm (22 ft. lbs.).





42. Route the drive belt (1) around the pulleys.
43. Position a hex-head socket on the belt tensioner pulley bolts.
44. Rotate the drive belt tensioner (2) clockwise to relieve the tension on the drive belt (1).
45. Install the drive belt (1) onto the tensioner (2).
46. Remove the crossmember to J 39580 security straps.
47. Lower the vehicle and install the engine and transmission to the vehicle.
48. Align the crossmember to the vehicle body.





49. Install the front crossmember bolts Tighten
^ Tighten the upper four cradle bolts to 125 Nm (92 ft. lbs.).
^ Tighten the lower two cradle bolts to 145 Nm (107 ft. lbs.).





50. Install the transmission support bolts.
^ Tighten the transmission support bolts to 57 Nm (42 ft. lbs.).
51. Raise and suitably support the vehicle. Refer to Vehicle Lifting.
52. Remove the J 39580 from below the vehicle.
53. Remove the supports from both steering knuckles.
54. Connect the ball stud to the steering knuckle.
55. Install the nuts and cotter pins to the left and right upper ball joints.
^ Tighten the upper ball joint nuts to 53 Nm (39 ft. lbs.).





56. Install the right and left lower shock bolts to the lower control arms.
^ Tighten the shock bolts to 65 Nm (48 ft. lbs.).
57. Lower the vehicle.
58. Install the transmission control, if equipped.
59. Install the floor shift control, if equipped.