CAUTION: If the engine encounters a catastrophic failure, the engine oil cooler must be replaced or damage to the new engine and/or components could result.
CAUTION: If the original engine has experienced a catastrophic failure or an individual failure with the piston, cylinder bore, engine block, valve or valve seat, the intake manifold MUST be replaced with a new manifold.
NOTE:
Do not use air tools to install (special tool #8984B, Fixture, Engine Lifting) (2, 3).
1. Install the engine lift fixture (2) (special tool #8984B, Fixture, Engine Lifting) and adapter (special tool #8984-UPD, Adapter, Engine Lift) (4).
2. Using a suitable engine hoist, lower the engine into the engine compartment.
3. Automatic transmission equipped vehicles, align the engine with the transmission.
4. Install two transmission bell housing to engine block bolts finger tight.
5. Lower the engine assembly until the engine mounts rest in the engine cradle crossmember.
6. Align the engine mounts, install both left/right engine mount to frame retaining bolts (2) and tighten to 68 N.m (50 ft. lbs.).
7. Position both left and right engine mount heat shields (4), install the retaining nuts (3) and tighten to 27 N.m (20 ft. lbs.).
8. Remove the engine hoist and the jack supporting the transmission.
9. Raise and support the vehicle.
10. Manual transmission equipped vehicles, install the transmission. Refer to INSTALLATION.
11. Automatic transmission equipped vehicles, install the oil pan to transmission bolts (1) and tighten to 54 N.m (40 ft. lbs.).
12. Install the remaining transmission bell housing to engine block bolts (2) and tighten to 68 N.m (50 ft. lbs.).
13. Rotate the crankshaft in clockwise direction and install all torque converter to flex plate bolts (1) finger tight.
14. Verify that the torque converter is pulled flush to the flex plate and tighten bolts to 88 N.m (65 ft.
lbs.).
15. Install the inspection cover (1) and tighten the retaining bolt (2) to 11 N.m (8 ft. lbs.).
NOTE:
The Crankshaft Position (CKP) sensor is located at the right rear side of the engine block.
16. Connect the CKP sensor electrical connector (1).
17. Position the starter motor (1) into the transmission.
18. Install the three starter motor retaining bolts (2) and tighten to 54 N.m (40 ft. lbs.).
19. Connect the solenoid wire to the starter motor (snaps in place).
20. Position the battery cable to the solenoid stud, install the battery cable eyelet nut and tighten to
11 N.m (8 ft. lbs.).
21. Position the starter heat shield (4) and install the retaining nuts (3).
22. Position the catalytic converters (4) onto the exhaust manifold flanges, install the flange nuts (3) and tighten to 41 N.m (30 ft. lbs.).
23. Connect the oxygen sensor electrical connectors (2).
24. Connect the right and left knock sensor (1) electrical connectors (5).
25. Install the heat shields onto both knock sensors (shield snaps on/off sensor).
26. Connect the transmission oil cooler lines to their retainers at the oil pan.
27. Install the lower radiator hose (1).
28. Lower the vehicle.
29. Remove the engine lift fixture (special tool #8984B, Fixture, Engine Lifting) (2) and adapter (special tool #8984-UPD, Adapter, Engine Lift) (4).
30. Position the left and right side wiring harness.
31. Lubricate the Oil Control Valve (OCV) rubber O-ring seal with clean engine oil.
32. Install the OCV (3) and rotate into position.
33. Install the OCV retaining bolt (2) and tighten to 11 N.m (8 ft. lbs.).
34. Connect the OCV electrical connector (1).
35. Position the heater core tube (3) into the water pump.
36. Install the heater core tube retaining bolt (1) and tighten to 11 N.m (8 ft. lbs.).
37. Connect the electrical connector to the coolant temperature (ECT) sensor (2).
38. Connect the camshaft position sensor electrical connector (1).
39. Install the intake manifold. Refer to MANIFOLD, INTAKE, INSTALLATION.
40. Connect the heater hoses (1, 2).
41. Connect the ground wires to the rear of each cylinder head.
42. Connect the ignition capacitor (2) electrical connector (1).
43. Position the power steering pump (4).
44. Install the three power steering pump (4) mounting bolts (2) through the access holes in the pulley and tighten the bolts to 28 N.m (21 ft. lbs.).
45. Connect the oil pressure sensor electrical connector (1).
46. Connect the oil temperature sensor electrical connector.
47. Position the generator (2) and install two generator mounting bolts (1) finger tight.
48. Raise and support the vehicle.
49. Position the generator support bracket (3) to the engine mount, install the retaining nut (1) finger
tight.
50. Position the generator support bracket (3) to the generator, install the retaining bolt (2) and
tighten to 65 N.m (48 ft. lbs.).
51. Tighten the generator support bracket (3) to engine mount retaining nut (1) to 28 N.m (21 ft.
lbs.).
52. Install the A/C compressor (3). Refer to COMPRESSOR, A/C, REMOVAL .
53. Position the belly pan and install the belly pan retainers (1).
54. Lower the vehicle.
55. Tighten two generator mounting bolts (1) to 65 N.m (48 ft. lbs.).
56. Snap the field wire connector into the rear of the generator.
57. Position the generator B+ terminal eyelet to the generator output stud, install the retaining nut
and tighten to 13 N.m (10 ft. lbs.).
58. Snap the plastic insulator cap onto the B+ output terminal.
59. Position the front section of the A/C suction line (2) into the engine compartment.
60. 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).
NOTE:
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.
61. Lubricate the new dual plane seal with clean refrigerant oil and position the seal onto the suction line fitting.
62. Connect the front section of the A/C suction line to the rear section of the A/C suction line.
63. 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 N.m (16 ft. lbs.).
64. Position the front section of the A/C liquid line into the engine compartment.
65. 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).
NOTE:
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.
66. Lubricate the new dual plane seal with clean refrigerant oil and position the seal onto the liquid
line fitting.
67. Connect the front section of the A/C liquid line to the rear section of the A/C liquid line.
68. 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 N.m (16 ft. lbs.).
69. Position the ignition coil electrical harness and connect all ignition coil electrical connectors (1).
70. Position the coolant bottle (1) and install the coolant bottle retaining bolts (2).
71. Install the Totally Integrated Power Module (TIPM) mounting bracket.
72. Install the TIPM. Refer to MODULE, TOTALLY INTEGRATED POWER (TIPM), REMOVAL .
73. Position the wire harness and secure to the right hand inner fender panel.
74. Rotate the accessory drive belt tensioner (8) clockwise until it contacts the stop and install the accessory drive belt (2) onto the pulleys, then slowly release the tensioner.
75. Install the cooling fan. Refer to FAN, COOLING, INSTALLATION .
76. Position the oil cooler hose (4) and Install oil cooler hose clamp (3).
77. Position the upper radiator hose (2) and Install the upper radiator hose clamp (1).
78. Install the strut tower support (6) and tighten bolts to 38 N.m (28 ft. lbs.).
79. Install the cowl panel cover (1). Refer to COVER, COWL PANEL, INSTALLATION .
80. Fill the crankcase with the specified type and amount of engine oil. Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS.
81. Fill the cooling system with the specified type and amount of engine coolant. Refer to STANDARD PROCEDURE.
82. Install the engine covers (1) onto the ball studs.
83. Connect the negative battery cable (3).
84. Perform the Refrigerant System Charge procedure. Refer to PLUMBING, STANDARD PROCEDURE .
85. Start the engine and inspect for leaks.
