Installation

Installation Procedure

Important:
The steps in the following procedure are in a specific order. Follow these steps in this order and ignore no details.





1. Install J41798 to the engine.
2. Install a lifting device to the J41798.
3. Install the engine to the crossmember.

Notice: Refer to Fastener Notice in Service Precautions.

4. Install the crossmember nuts to the engine mount.
- Tighten the engine mount nuts to 54 Nm (40 ft. lbs.).
5. Install the spark plugs to the cylinder heads.
6. Install the spark plug wires to the spark plugs.
7. Install the AIR pipe and mounting bolts to the exhaust manifolds.
- Tighten the AIR pipe to 20 Nm (15 ft. lbs.).
8. Install the AC compressor bracket and bolt to the engine.
- Tighten the AC compressor bracket bolts to 50 Nm (37 ft. lbs.).
9. Install the AC compressor mounting stud to the engine.
- Tighten the AC compressor mounting stud to 9 Nm (80 inch lbs.).
10. Install the AC compressor to the AC bracket.
11. Install the AC compressor belt.
12. Install the PS pump and reservoir to the engine.
13. Install the PS pump mounting bolts.
- Tighten the PS pump mounting bolts to 25 Nm (118 ft. lbs.).
14. Install the PS pump pulley to the pump using J25033-B.





15. From the new engine, remove the generator mounting bolts.
16. Remove the generator.
17. Remove the generator mounting bracket bolt and bracket.
18. Roll the engine and crossmember assembly underneath the vehicle.
19. Partially lower the vehicle to the engine and crossmember assembly.
20. Install the ground strap to the rear of the left cylinder head.
- Tighten the ground strap bolt to 32 Nm (24 ft. lbs.).
21. Install the AIR tube bracket bolt and the bracket.





22. Route the electrical harnesses and connect the following electrical connectors at the rear of the engine:
22.1. Engine oil pressure sensor
22.2. Camshaft position sensor
22.3. MAP sensor
22.4. Knock sensor wire harness connector
22.5. All remaining electrical connections at the rear of the engine





23. Vehicles equipped with a manual transmission, slide the engine and crossmember assembly rearward. Do not force the engine onto the propeller spline.
24. Position the engine to the proper height and angle in order to install the propeller input shaft.
25. Insert the propeller input shaft into the clutch driven plate hub while maintaining the proper angle, Do Not Force. Rotate the shaft slightly to bring the two splines into alignment, if necessary.





26. Slowly seat the engine flywheel housing to the driveline.
27. Install the front driveline support bolts.
- Tighten the engine flywheel housing to the driveline support assembly bolts to 50 Nm (37 ft. lbs.).
28. Clip the clutch actuator hose to the engine flywheel housing clip.
29. Connect the master cylinder hose to the clutch actuator hose.

Important: Do not tighten the flywheel hub collar bolt at this time.





30. Vehicles equipped with an automatic transmission, slide the engine and crossmember assembly rearward. Do not force the engine onto the propeller spline.
31. Position the engine to the proper height and angle in order to install the propeller input shaft.
32. Install the front driveline support bolts.
- Tighten the engine flywheel housing to the driveline support assembly bolts to 50 Nm (37 ft. lbs.).
33. Hand tighten the flywheel hub collar bolt.
34. Install the AIR tube bracket and mounting bolts to the left cylinder head.
- Tighten the AIR tube to 50 Nm (37 ft. lbs.).
35. Lower the vehicle onto the crossmember and align the dowels.

Important: Use only hand tools when tightening or torquing crossmember nuts.

36. By HAND, install new crossmember nuts.
- Tighten the crossmember nuts to 110 Nm (81 ft. lbs.).
37. Raise the vehicle.
38. Clip the wiring harness to the rear of the engine.
39. Remove J42203 from the vehicle.





40. Vehicles equipped with an automatic transmission, remove the previously installed M10 - 1.5 x 55mm bolts from the front of the driveline support assembly.
41. Install two plugs in the driveline support assembly.
- Tighten the plugs to 50 Nm (37 ft. lbs.).





42. Connect the automatic transmission cooler pipes at the engine flywheel housing junction (if equipped).
- Tighten the automatic transmission cooler pipes to 27 Nm (20 ft. lbs.).
43. Connect the automatic transmission cooler pipes to the front and the rear of the oil pan (if equipped).





44. Install the front transverse leaf spring.





45. Install the shock absorber lower mounting bolts.
- Tighten the shock absorber lower mounting bolts to 28 Nm (21 ft. lbs.).
46. Install the ABS electrical connector clips to the crossmember.
47. Install the EVO electrical connector clips to the crossmember.
48. Install RTD electrical connector clips to the crossmember (if equipped).





49. Remove J33432-A from the spring.
50. Install the radiator.





51. Install the electric cooling fan assembly to the radiator by sliding the whole unit into the slots provided.





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





53. Install the front stabilizer shaft to the lower control arms.
54. Install the wiring harness ground wires to the left side of the engine.





55. Connect the left front H02S sensor connector.
56. Connect the engine oil temperature sensor connector.





57. Install the AC compressor hose assembly to the compressor.
58. Install the AC compressor line retaining bolt.
- Tighten the AC compressor hose mounting bolts to 35 Nm (26 ft. lbs.).





59. Connect the right front H02S sensor connector.
60. Connect the crank position sensor connector.
61. Connect the oil level sensor connector.
62. Install the wiring harness ground wires to the right side of the engine block.





63. Install the starter.





64. Install the driveline close-out panel.
65. Install the driveline close-out panel bolts.
- Tighten the close-out panel bolts to 12 Nm (106 inch lbs.).
66. Install the intermediate exhaust pipe and hangers.
67. Install the H02S sensors and clip harness.
68. Install the front tire and wheel assemblies.
- Tighten the wheel nuts to 140 Nm (100 ft. lbs.).

69. Lower the vehicle.





70. Connect the automatic transmission cooler pipes to the radiator (if equipped).





71. Connect the AIR hose to the left exhaust manifold.





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





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





75. Install the generator mounting bracket.
76. Install the generator mounting bracket bolt.
- Tighten the generator mounting bracket bolt to 50 Nm (37 ft. lbs.).
77. Install the generator.
78. Install the generator mounting bolts.
- Tighten the generator mounting bolts to 50 Nm (37 ft. lbs.).





79. Connect the generator electrical connectors.
- Tighten the nuts to 13 Nm (10 ft. lbs.).





80. Connect the following electrical connectors from the top of the engine:
80.1. Fuel injectors
80.2. Ignition coil main connectors
80.3. EVAP solenoid
80.4. Electric throttle motor
80.5. Throttle position sensor
80.6. ECT sensor
80.7. AC compressor





81. Connect the heater hoses to the water pump.





82. Connect the radiator hoses to the water pump.





83. Connect the fuel line to the fuel rail (1).





84. Install the fuel rail covers.





85. Install the accessory drive belt (5).





86. Install the Electronic Brake Control Module/Break Pressure Modulator Valve (EBTCM/BPMV) and bracket (1).
87. Install the top radiator hose.
88. Install the upper radiator support.





89. Reposition the air intake duct and the air cleaner assembly.





90. Connect the IAT sensor connector.
91. Connect the MAF sensor connector.





92. Connect the negative battery cable.
- Tighten the negative battery cable bolt to 15 Nm (11 ft. lbs.).
93. Fill or top off the engine with oil.
94. Refill the cooling system.
95. Recharge the AC system.
96. Program the Transmitters.
97. Check and fill the transmission fluid.





98. With automatic transmission vehicles use the following steps:
98.1. Start the engine and warm to operating temperature.
Idle or for at least 10 minutes.
98.2. Shut off the engine.
98.3. Allow engine to cool to room temperature.
98.4. Raise the vehicle.
98.5. Tighten the hub collar bolt (1).
- Tighten the flywheel hub collar bolt to 130 Nm (96 ft. lbs.).
99. Install the engine flywheel housing inspection plug.
100. Check the engine for problems.
101. Perform a wheel alignment.