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Installation - Engine Assembly

WARNING: This page is about a different car, the 2006 Chrysler PT Cruiser. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Positioning Engine - Removal/Installation
GC0042376Courtesy of DAIMLERCHRYSLER CORP.
1 - SAFETY STRAPS
2 - CRADLE 6710
3 - WOODEN BLOCK
4 - POST KIT ENGINE CRADLE 6848
5 - PLACE REAR POSTS INTO LOCATING HOLES
  1. Position engine and transmission assembly under vehicle and slowly lower the vehicle over the engine/transaxle assembly.
    Fig 2: Left Mount Bolts
    GC0042382Courtesy of DAIMLERCHRYSLER CORP.
    1 - BOLT
    2 - TRANSAXLE
    3 - LEFT MOUNT
  2. Continue lowering vehicle until engine/transaxle aligns to mounting locations. Install mounting bolts (1) at the left engine/transaxle mounts.
    Fig 3: Engine Mounting - Right Side
    GC0042383Courtesy of DAIMLERCHRYSLER CORP.
    1 - BOLTS
    2 - RIGHT FENDER
    3 - UPPER TORQUE STRUT BRACKET
    4 - NUTS
    5 - BOLT
    6 - UPPER TORQUE STRUT
    7 - ENGINE MOUNT BRACKET
    8 - BOLT
    9 - LOWER TORQUE STRUT
    10 - BOLT
    11 - RIGHT ENGINE MOUNT
  3. Install mounting bolts at the right engine/transaxle mounts. Tighten right and left engine mount bolts to 118 N.m (87 ft. lbs.).
    Fig 4: Upper Torque Strut
    GC0021432Courtesy of DAIMLERCHRYSLER CORP.
    1 - UPPER TORQUE STRUT
    2 - TORQUE STRUT FASTENERS
  4. Install the upper engine torque strut (1). See Fig 4.
  5. Remove safety straps from engine/transaxle assembly. Slowly raise vehicle enough to remove the engine Dolly 6135 and Cradle 6710.
  6. Raise vehicle.
    Fig 5: Clutch Slave Cylinder/Damper
    GC0042375Courtesy of DAIMLERCHRYSLER CORP.
    1 - DAMPER FASTENERS
    2 - CLUTCH SLAVE CYLINDER FASTENERS
  7. Install A/C compressor mounting bolts. Reconnect A/C compressor electrical connectors.
  8. Connect power steering pressure line to power steering pump.
  9. Install fasteners securing clutch slave cylinder and damper. See Fig 5.
  10. Connect exhaust pipe to exhaust manifold. Install fasteners and torque to 28 N.m (250 in. lbs.).
  11. Install left and right drive axles (Refer to DIFFERENTIAL & DRIVELINE/HALF SHAFT - INSTALLATION) .
    Fig 6: Lower Torque Strut
    GC0042374Courtesy of DAIMLERCHRYSLER CORP.
    1 - PENCIL STRUT
    2 - TORQUE STRUT FASTENERS
    3 - LOWER TORQUE STRUT
  12. Install pencil strut and lower torque strut. See Fig 6.
  13. Install accessory drive belt (Refer to COOLING/ACCESSORY DRIVE/DRIVE BELT - INSTALLATION) .
  14. Install accessory drive belt splash shield.
  15. Install both front wheels.
  16. Lower vehicle.
  17. Connect fuel line to fuel rail.
  18. Connect power steering reservoir hose to power steering pump. Install fastener securing power steering return line to right engine bracket. Install fasteners securing power steering reservoir bracket to right engine bracket.
  19. Connect ground strap to cylinder head.
  20. Connect brake booster and purge solenoid vacuum hoses.
  21. Connect transmission shift cables and transmission electrical connectors.
  22. Install cooling module assembly (fan, radiator, A/C condenser). Connect radiator fan electrical connector.
  23. Connect A/C lines at junction near upper torque strut.
    Fig 7: PDC Bracket Attaching Bolts
    GC0042379Courtesy of DAIMLERCHRYSLER CORP.
    1 - PDC
    2 - PDC BRACKET BOLTS
    3 - BATTERY TRAY BOLT
  24. Connect upper A/C line to A/C condenser.
  25. Connect upper and lower radiator hoses.
  26. Install upper radiator crossmember (Refer to BODY/EXTERIOR/RADIATOR CROSSMEMBER - INSTALLATION) .
  27. Connect heater hoses to thermostat housing and heater return tube.
  28. Connect coolant recovery container hose to radiator neck.
  29. Install bolts attaching Power Distribution Center (PDC) (1). Connect positive cable to PDC and ground wire to vehicle body. See Fig 7.
  30. Connect engine wiring harness at Powertrain Control Module (PCM).
    Fig 8: Battery Tray-Removal/Installation
    GC0042378Courtesy of DAIMLERCHRYSLER CORP.
    1 - BATTERY TRAY
  31. Install battery tray (1). See Fig 8.
    Fig 9: Battery-Removal/Installation
    GC0042377Courtesy of DAIMLERCHRYSLER CORP.
    1 - BATTERY
  32. Install battery (1). Connect positive battery cable.
  33. Connect negative battery cable.
    Fig 10: Air Cleaner Housing
    GC0021466Courtesy of DAIMLERCHRYSLER CORP.
  34. Install air cleaner housing (1) and throttle body air inlet hose.
  35. Install new oil filter. Fill engine crankcase with proper oil to correct level.
  36. Fill power steering system.
  37. Fill Cooling system (Refer to COOLING/ENGINE - STANDARD PROCEDURE) .
  38. Evacuate and recharge A/C system (Refer to HEATING & AIR CONDITIONING - STANDARD PROCEDURE) .
  39. Start engine and run until operating temperature is reached.
  40. Perform torque strut adjustment procedure (Refer to ENGINE/ENGINE MOUNTING/TORQUE STRUT - ADJUSTMENTS)  .
  41. Adjust transmission linkage, if necessary.
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