Engine Installation

CAUTION: The steps in the following procedure are in a specific order. Follow these steps in this order and ignore no details or vehicle damage could occur.





1. Install the engine to the front cradle.
2. Install the engine mount to cradle nuts. Tighten the engine mount nuts to 54 Nm (40 ft. lbs.).
3. Install the P/S pump and reservoir to the engine. Tighten the P/S pump mounting bolts to 25 Nm (18 ft. lbs.).





4. Partially lower the vehicle to the engine and front cradle assembly.
5. Route the electrical harnesses and connect the following electrical connectors:
a. Engine oil pressure gauge
b. Camshaft position sensor
c. Manifold absolute pressure sensor
d. Knock sensor
e. Ground on rear of LH head
f. All remaining electrical connections at the rear of the engine

NOTE: Do not tighten the flex plate hub collar bolt at this time.

6. Slide the engine and front cradle assembly rearward and install the propeller shaft spline to the engine. Do not force the engine onto the propeller splice.





7. Install the front driveline support bolts. Tighten the engine flex plate housing to driveling support assembly bolts to 50 Nm (37 ft. lbs.).
8. Lower the vehicle on to the cradle and align dowels.
9. BY HAND, Install NEW front cradle nuts. Tighten the front cradle nuts to 110 Nm (81 ft. lbs.).
10. Raise the vehicle.





11. Remove driveline support strap from the vehicle.





12. Install a transverse leaf spring compressor to the front spring.
13. Compress the front transverse spring.





14. Install the lower shock absorber mounting bolts. Tighten the shock absorber mounting bolts to 28 Nm (20 ft. lbs.).





15. Connect the lower ball joints to the steering knuckles. Tighten the lower ball joint nuts to 75 Nm (55 ft. lbs.).





16. Install the tie rod ends (5) to steering knuckles (4). Tighten the tie rod end nuts (3) to 45 Nm (33 ft. lbs.).
17. Install the ABS electrical connectors at the cradle.
18. Install the EVO electrical connector at the cradle.
19. Install Real Time Dampening (RTD) electrical connectors at the cradle. (if equipped)





20. Remove transverse leaf spring compressor from the vehicle.





21. With automatic transmission vehicles use the following steps:
a. Remove the previously installed M10-1.5 x 55mm bolts from the front of the driveling support assembly.
b. Install the plugs to the front of the driveline support assembly. Tighten the plugs to 50 Nm (37 ft. lbs.).





22. Connect the automatic transmission oil cooler lines to the radiator. (if equipped) Tighten the cooler lines to 27 Nm (20 ft. lbs.).





23. Connect the automatic transmission cooler lines at the engine flex plate housing junction. (if equipped) Tighten the automatic transmission cooler lines to 27 Nm (20 ft. lbs.).





24. Install both electric cooling fans.
25. Install the electric cooling fan bolts. Tighten the electric cooling fan bolts to 10 Nm (89 inch lbs.).





26. Connect the electrical connectors and harness to the electric cooling fans.





27. Install the front stabilizer bar to the front cradle.
28. Install the front stabilizer mounting bolts and straps. Tighten the front stabilizer mounting bolts to 54 Nm (40 ft. lbs.).





29. Connect the LH front H02S connector.
30. Connect all the grounds on the left side of the engine block.
31. Connect the engine oil temperature sensor connector.





32. Install the A/C compressor hose to the A/C compressor.
33. Install the A/C compressor line retaining bolt. Tighten the A/C compressor hose mounting bolts to 35 Nm (26 ft. lbs.).





34. Connect the RH front H02S connector.
35. Connect the crank position sensor connector.
36. Connect the oil level sensor connector.





37. Install the starter.
38. Install the starter mounting bolts. Tighten the starter mounting bolts to 50 Nm (37 ft. lbs.).





39. Install all the grounds on the RH side of the engine block.
40. Connect the positive battery cable to the starter. Tighten positive battery cable nut to 15 Nm (11 ft. lbs.).
41. Connect the S terminal wire to the starter. Tighten S terminal wire nut to 4 Nm (35 inch lbs.).





42. Install the close-out panel.
43. Install the close-out panel bolts. Tighten the close-out panel bolts to 12 Nm (102 inch lbs.).
44. Install the intermediate exhaust pipe. See Exhaust System.
45 Install the front tire and wheel assemblies. Tighten the wheel nuts to 140 Nm (100 ft. lbs.).
46. Lower the vehicle.





47. Connect the AIR hose to the LH exhaust manifold.





48. Connect the intermediate steering shaft to the steering gear.
49. Install the intermediate steering shaft bolt. Tighten the intermediate steering shaft bolt to 48 Nm (35 ft. lbs.).





50. Connect the brake booster vacuum hose to the brake booster.





51. Install the generator.
52. Install the generator mounting bolts. Tighten the generator mounting bolts to 50 Nm (37 ft. lbs.).





53. Install the generator rear bracket.
54. Install the generator rear bracket bolts. Tighten the generator rear bracket mounting bolts to 50 Nm (37 ft. lbs.).





55. Connect the generator electrical connectors. Tighten the nut to 13 Nm (10 ft. lbs.).





56. Connect the following electrical connectors:
a. Fuel injectors
b. Ignition coil main connectors
c. EVAP solenoid
d. Electric throttle motor
e. Throttle position sensor
f. ECT sensor
g. A/C compressor





57. Connect the heater hoses to the water pump.





58. Connect the radiator hoses to the water pump.





59. Connect the fuel lines at the fuel rail. (3 and 4)





60. Install the fuel rail covers.





61. Install the generator accessory drive belt. (5)





62. Install the air intake duct and the air cleaner assembly.
63. Connect the fuel regulator purge line to the air intake duct.





64. Connect the intake air temperature sensor connector.
65. Connect the MAE sensor connector.





66. Connect the negative battery cable. Tighten the negative battery cable bolt to 15 Nm (11 ft. lbs.).
67. Fill or top off the engine with oil.
68. Refill the cooling system. See Cooling System.
69. Recharge the A/C system. See Heating and Air Conditioning.
70. With automatic transmission vehicles use the following steps:
a. With the flex plate hub collar bolt removed, start the engine and warm to operating temperature. Idle or drive for at least 10 minutes.
b. Shut off the engine.
c. Allow engine to cool to room temperature.
d. Install hub collar bolt. Tighten the flex plate hub collar bolt to 130 Nm (96 ft. lbs.).
71. Check the engine for problems.