Engine - Installation

INSTALLATION




1. Position engine in the vehicle.
Position both the left and right side engine mount brackets and install the through bolts and nuts. Tighten nuts to 4X2 vehicles 95 Nm (70 ft. lbs.). 4X4 vehicles 102 Nm (75 ft. lbs.).
2. 4X4 vehicles Install locknuts onto the engine mount brackets. Tighten locknuts to 41 Nm (30 ft. lbs.).
3. Remove jack from under the transmission.
4. Remove Engine Lifting Fixture Special Tool 8347 (3).
5. Remove Special Tools 8400 Lifting Studs.








6. Position generator wiring behind the oil dipstick tube, then install the oil dipstick tube upper mounting bolt.
7. Connect both left (2) and right (3) side body ground straps.
8. Install power steering pump.
9. Connect fuel supply line quick connect fitting.
10. Connect the vacuum lines at the throttle body and intake manifold.




11. Connect engine harness at the following points:
- Intake Air Temperature (IAT) Sensor (4)
- Idle Air Control (IAC) Motor (3)
- Fuel Injectors
- Throttle Position (TPS) Switch (2)
- Engine Oil Pressure Switch
- Engine Coolant Temperature (ECT) Sensor
- Manifold Absolute Pressure (MAP) Sensor
- Camshaft Position (CMP) Sensor
- Coil Over Plugs




12. Position and install heater hoses (1) and tubes onto intake manifold.
13. Install the heater hoses onto the heater core and the engine front cover, and install clips (2).




14. Install generator (3).
15. Install A/C condenser, radiator and transmission oil cooler.
16. Connect radiator upper and lower hoses.
17. Connect the transmission oil cooler lines to the radiator.
18. Install accessory drive belt, fan assembly and shroud.




19. Install A/C compressor (2).




20. Install both breathers (1). Connect tube to both crankcase breathers.
21. Connect throttle and speed control cables.
22. Install throttle body resonator assembly and air inlet hose. Tighten clamps 4 Nm (35 in. lbs.).
23. Raise vehicle.




24. Install transmission to engine mounting bolts. Tighten the bolts to 41 Nm (30 ft. lbs.).
25. Install torque converter bolts (Automatic Transmission Only).
26. Connect crankshaft position sensor (1).
27. 4X4 vehicles Position and install the axle isolator bracket onto the axle, transmission and engine block. Tighten bolts to specification.




28. Install starter (4).





CAUTION: The structural cover requires a specific torque sequence. Failure to follow this sequence may cause severe damage to the cover.

29. Install structural cover.
30. Install exhaust crossover pipe.
31. Install engine block heater power cable, If equipped.
32. 4X4 vehiclesConnect axle vent tube to left side engine mount.
33. Lower vehicle.
34. Check and fill engine oil.
35. Recharge the A/C system.
36. Refill the engine cooling system.
37. Connect the battery positive and negative cables.
38. Start the engine and check for leaks.