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Home >> Chrysler >> 2003 >> Intrepid SXT >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> 3.5L >> Engine 3.5L >> Installation - Engine Assembly

Installation - Engine Assembly

  1. Attach lifting device and lower engine into engine compartment.
  2. Align engine mounts and install fasteners but do not tighten  until all mounting bolts have been installed.
  3. Install transmission case to engine block tighten bolts to 102 N.m (75 ft. lbs.).
  4. Remove engine lifting device.
  5. Raise vehicle.
  6. Tighten engine mount fastener to 61 N.m (45 ft. lbs.).
  7. Align flex plate to torque converter and install mounting bolts. Tighten bolts to 75 N.m (55 ft. lbs.).
  8. Install crankshaft position sensor. (Refer to CRANKSHAFT POSITION SENSOR ).
  9. Install starter. (Refer to STARTERS ).
  10. Install new V-Band clamp at left side exhaust manifold to catalytic converter. Tighten V-Band clamp to 11 N.m (100 in. lbs.).
  11. Install left side catalytic converter down pipe support fastener at transaxle. Tighten fastener to 47 N.m (35 ft. lbs.).
  12. Tighten the left converter down pipe band clamp.
  13. Install the transmission oil cooler lines bracket to engine.
  14. Install structural collar/cover. (Refer to INSTALLATION )
  15. Lower vehicle.
  16. Connect all electrical connections.
  17. Install four upper transmission to block bolts tighten to 102 N.m (75 ft. lbs.).
  18. Install water pipe and retaining fasteners to the transaxle/cylinder block double-ended bolts.
  19. Install rear throttle body support bracket.
  20. Connect heater hoses.
  21. Install upper intake manifold. (Refer to INTAKE MANIFOLD - UPPER ).
  22. Connect ground straps at both cylinder heads.
  23. Connect all vacuum hoses.
  24. Connect coolant hoses at coolant recovery/pressure container.
  25. Connect throttle and speed control cables to bracket and throttle arm.
  26. Connect fuel line.
  27. Install new V-Band clamp at right exhaust manifold. Tighten V-Band clamp to 11 N.m (100 in. lbs.).
  28. Install and tighten right side catalytic converter down pipe support bracket fastener at transaxle mount.
  29. Install air conditioning compressor and tighten fasteners to 28 N.m (250 in. lbs.).
  30. Install power steering pump and tighten fasteners to 28 N.m (250 in. lbs.).
  31. Install generator. (Refer to GENERATORS & REGULATORS ).
  32. Install radiator. (Refer to RADIATOR ).
  33. Attach air conditioning condenser to radiator.
  34. Install power steering line bracket to radiator.
  35. Connect engine oil and transmission cooler lines to radiator.
  36. Install lower radiator hose.
  37. Install upper radiator hose.
  38. Install accessory drive belts. (Refer to ACCESSORY DRIVE ).
  39. Install radiator fan. (Refer to RADIATOR FAN ).
  40. Fill cooling system. (Refer to STANDARD PROCEDURE ).
  41. Fill engine with proper amount of oil.
  42. Connect hood release cable to hood latch and install upper radiator crossmember.
  43. Install air cleaner and air inlet hose.
  44. Install strut tower brace.
  45. Install both cowl covers.
  46. Install both wiper arms.
  47. Install hood.
  48. Connect negative cable.
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