Installation

1. Check the data plate to verify that the replacement engine is the same model and rating as the engine that was removed.
2. Install all accessories and brackets that had been removed from the previous engine.
3. Use the lifting brackets to lift the engine off of the stand.
4. Position the engine in the chassis with the thru-bolt installed.
5. Remove the covers or tape covering the engine openings.
6. Raise and support the vehicle.
7. Refer to Transmission and Drivetrain for transmission installation.
8. Install the dust shield and transmission cover.
9. Install the prop shaft.
10. Install the starter motor. Connect the starter wires.
11. Install the transmission cooler line brackets to oil pan.
12. Install and tighten engine front mount thru-bolt nuts.
13. Install the oil pan. Install the drain plug.
14. Lower the vehicle.
15. On Manual Transmission vehicles, install the shift lever.
16. Connect the fuel lines to the lift pump and fuel return. Use tags to identify the lines.
17. Connect all electrical connections to the engine. Use tags to identify their locations.
18. Connect the transmission cooler lines.
19. Connect the power steering hoses, if equipped.
20. Connect the accelerator linkage, the speed control linkage and the throttle valve linkage.
21. Install the outlet duct. Connect the intercooler outlet duct to the air inlet housing and the intercooler.
22. Install the inlet duct. Connect the intercooler inlet duct to the turbocharger and the intercooler.
23. Install the exhaust pipe to the turbocharger outlet flange.
24. Install the air inlet tube. Connect the air inlet tube to the turbocharger and the air intake housing.
25. Connect the heater hoses at the dash panel and at the water valve.
26. Install the generator and wire connections.
27. Install the radiator.
28. Connect the lower radiator hose.
29. Install the fan shroud.
30. Install the fan.
31. Connect the top radiator hose.
32. Install the radiator overflow bottle.
33. Install the washer bottle.
34. If equipped, install the condenser.
35. Install the A/C compressor with the lines attached.
36. Evacuate and charge the air conditioning system, if equipped.
37. Install the transmission oil cooler.
38. Install the upper crossmember and top core support.
39. Install the serpentine belt.
40. Fill the cooling system with a mixture of 50% water and 50% ethylene-glycol base antifreeze.
41. Fill the engine with the required amount of clean engine lubricating oil.
42. Install the battery and connect the battery cables.
43. Check the oil level after the engine has run for 2 or 3 minutes. Oil held in the oil filter and oil passages will cause the oil level in the pan to be lower than normal for a short period of time.
44. Operate the engine at idle for 5 to 10 minutes and check for leaks and loose parts.