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Installation - Engine Assembly

  1. Attach Special Tool 8342, Engine Lifting Fixture to engine (Figure). Lower engine into engine compartment.
    CAUTION: Do not  tighten the transaxle case to engine block bolts until all bolts have been hand started, and the two mating surfaces are completely joined together, as damage to cylinder block or transaxle could occur.
  2. Align engine mounts and install fasteners but do not tighten  until all mounting bolts have been installed.
  3. Install transaxle case to engine block bolts and tighten to 102 N.m (75 ft. lbs.).
  4. Remove 8342 Engine Lifting Fixture.
  5. Tighten left and right engine mount isolator to engine mount bracket fasteners to 61 N.m (45 ft. lbs.).
  6. Raise vehicle.
  7. Align flex plate to torque converter. Install mounting bolts and tighten to 75 N.m (55 ft. lbs.).
  8. Install crankshaft position sensor. (Refer to CRANKSHAFT POSITION SENSOR )
  9. Install starter. (Refer to STARTER MOTOR )
  10. Install the transaxle oil cooler lines bracket to engine.
  11. Install structural collar to oil pan and transaxle. (Refer to STRUCTURAL COLLAR/COVER )
  12. Lower vehicle.
  13. Install rear throttle body support bracket.
  14. Install electrical harness and fuel line support brackets to the throttle body support bracket.
  15. Install fastener attaching electrical harness bracket to the transaxle to block bolt.
  16. Connect heater hoses.
  17. Connect all ground straps to engine.
  18. Connect all vacuum hoses and electrical connectors.
  19. Connect both hoses at coolant pressure/recovery container.
  20. Connect throttle and speed control cables.
  21. Connect fuel line. (Refer to FUEL LINE DISCONNECT FITTINGS )
    NOTE: Do not reuse V-Band clamps.
  22. Install new V-Band clamps at exhaust manifolds and tighten to 11 N.m (100 in. lbs.).
  23. Install catalytic converter down pipe front and rear supports.
  24. Install air conditioning compressor. (Refer to A/C COMPRESSOR - MANUAL A/C or A/C COMPRESSOR - AUTO A/C )
  25. Install power steering pump. (Refer to INSTALLATION - PUMP (2.7L ENGINE) )
  26. Install radiator. (Refer to RADIATOR )
  27. Connect engine oil cooler lines to radiator (if equipped).
  28. Connect transmission oil cooler lines to radiator.
  29. Attach A/C condenser to radiator.
  30. Install lower radiator hose.
  31. Install upper radiator hose.
  32. Install accessory drive belts. (Refer to DRIVE BELTS - 2.7L )
  33. Install radiator fan. (Refer to RADIATOR FAN ASSEMBLY )
  34. Refill cooling system. (Refer to STANDARD PROCEDURE - COOLING SYSTEM FILLING )
  35. Fill engine with proper amount of oil.
  36. Connect hood release cable to hood latch and install radiator upper crossmember. (Figure)
    1. Place in position the radiator upper crossmember.
    2. Connect hood latch cable to hood latch.
    3. Install bolts attaching upper radiator closure panel. Check bolt alignment marks.
    4. Install bolts attaching the forward edge of upper radiator closure panel.
    5. Install fasteners attaching the forward edge of radiator upper crossmember.
    6. Install fasteners attaching upper bumper fascia.
    7. Install fasteners attaching upper bumper fascia.
    8. Install headlamp jackscrews both sides.
    9. Check hood operation.
  37. Install air cleaner and air inlet hose.
  38. Install cowl support. (Refer to Figure)
  39. Install right and left cowl screens. (Refer to Figure)
  40. Install both wiper arms. (Refer to WIPER ARMS )
  41. Install hood.
  42. Connect negative cable to remote jumper terminal at right strut tower.
  43. Start engine and operate until operating temperature is reached.
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