INSTALLATION - ENGINE ASSEMBLY




1. Position the engine in the vehicle.
2. Install the transmission bellhousing to engine mounting bolts (Refer to 21 - TRANSMISSION/TRANSAXLE/MANUAL - INSTALLATION) (Refer to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC - 42RLE - INSTALLATION).
3. Tighten the engine mount thru bolts (Refer to 9 - ENGINE/ENGINE MOUNTING/FRONT MOUNT - INSTALLATION).
4. Install the torque converter bolts. (If equipped) (Refer to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC - 42RLE - INSTALLATION).
5. Install the structural cover (1) (Refer to 9 - ENGINE/ENGINE BLOCK/STRUCTURAL COVER - INSTALLATION).


6. Install the crank position sensor (2) (CKP).


7. Install the starter (1) (Refer to 8 - ELECTRICAL/STARTING/STARTER MOTOR - INSTALLATION).


8. Install the flex plate inspection cover. (If equipped).
9. Connect the starter wiring (1) (Refer to 8 - ELECTRICAL/STARTING/STARTER MOTOR - INSTALLATION).


10. Connect the knock sensor electrical connector.
11. Install the left and right exhaust manifolds.
12. Connect the exhaust system and connect the right side O2 sensors (1,2).


13. Connect the left side O2 sensors (1,2).
14. Connect the in block heater (if equipped).
15. Connect the coolant hose at the engine oil cooler.


16. Connect the oil pressure sending unit (OPS) wiring harness connector.
17. Install the upper intake manifold (3) (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD - INSTALLATION).


18. Install the EGR tube (1) (Refer to 25 - EMISSIONS CONTROL/EXHAUST GAS RECIRCULATION/VALVE - INSTALLATION).
19. Connect the engine vacuum harnesses.


20. Route the engine harness to the left cylinder head and attach the purge solenoid.
21. Connect the throttle position (TP), idle air control (IAC) motor, oxygen (H02), cam position (CMP), manifold absolute pressure (MAP) (2), and the engine wiring harness connectors.


22. Connect the A/C discharge line (2) at the compressor (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/A/C COMPRESSOR - INSTALLATION).


23. Connect the A/C suction line (2) at the compressor and compressor electrical connector (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/A/C COMPRESSOR - INSTALLATION).


24. Install the power steering pump (1) (Refer to 19 - STEERING/PUMP - INSTALLATION).


25. Connect the fuel line (4) to the fuel rail.


26. Install the generator (3) (Refer to 8 - ELECTRICAL/CHARGING/GENERATOR - INSTALLATION).


27. Reconnect the generator wiring. (1,2) (Refer to 8 - ELECTRICAL/CHARGING/GENERATOR - INSTALLATION).
28. Install the drive belt.


29. Connect the radiator, coolant reservoir and heater hoses.
30. Connect the throttle wiring harness (ETC) (3).


31. Install the PCV hose (1).
32. Fill the cooling system (Refer to 7 - COOLING - STANDARD PROCEDURE).


33. Install the air cleaner housing, inlet hose (1) and inlet air temp sensor (IAT) (2) (Refer to 9 - ENGINE/AIR INTAKE SYSTEM/AIR CLEANER ELEMENT - INSTALLATION).
34. Evacuate and recharge A/C system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT - STANDARD PROCEDURE).
35. Install new oil filter. Fill engine crankcase with proper oil to correct level (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - SPECIFICATIONS).




36. Install the front splash shield (1).
37. Connect negative cable to battery.
38. Start engine and run until operating temperature is reached.