Installation Procedure

Installation Procedure
1. Install the engine mount brackets with the engine mounts.
2. Use a floor crane in order to install the engine to the frame.
3. Install the ECM with the ECM bracket.
4. Install the water outlet.
5. Install the block heater.
6. Install the flywheel.
7. Install the intake manifold.
8. Install the crankshaft balancer.
9. Install the right exhaust manifold.
10. Install the oil filter adapter.
11. Install the left exhaust manifold.
12. Install the oil level indicator.
13. Install the generator and the generator bracket.
14. Install the power steering pump.
15. Install the power steering reservoir to the engine.
16. Install the A/C compressor.
17. Install the A/C compressor and power steering drive belt tensioner.
18. Install the generator and water pump drive belt tensioner.
19. Install the drive belts.
20. Install the bolts that secure the transmission to the engine and the flywheel to the torque convertor.
21. Install the starter motor.
22. Remove EN 46114 from the engine.
23. Install the CRFM with the radiator hoses to the frame.
24. Connect the power steering cooler hoses to the CRFM.
25. Connect the radiator hoses to the water outlet housing and the coolant inlet pipe.
26. Install the transmission oil cooler pipes to the engine, radiator and the transmission.
27. Install the engine wiring harness and related components.





28. Install the HO2S connector bracket (1) to the left cylinder head.
29. Install the thermostat housing with the heater pipes, heater hoses and surge tank outlet hose.
30. Install the catalytic converters with the oxygen sensors.
31. Install the fuel lines to the fuel rail and the EVAP purge solenoid.





32. Connect the ECM chassis side electrical connector.

33. Important: Ensure that all the hoses, wires, pipes and shock modules clear the vehicle during the installation process.

With the aid of an assistant, raise the table or lift the vehicle to install the engine, transmission, front frame and front suspension assembly to the vehicle.





34. Install the front frame bolts (2).
35. Install the transmission support to underbody bolts.
36. Remove the powertrain lift/support table.





37. Install the upper mounting bolts to the right and left shock module.
38. Secure the shock modules to the front frame with mechanics wire to avoid stretching the front brake hoses.
39. Install the headlamp leveling sensors.





40. Connect the transmission shift linkage to the transmission.
41. Connect electrical connector to the low oil level sensor.





42. Install the lower engine mount nuts.
43. Install the lower intermediate steering shaft .
44. Install the front tire and wheel assemblies.
45. Install the front brake pipes and retainers to the underbody.
46. Connect the rear brake pipes to the BPMV.
47. Connect the side air baffles to the radiator.
48. Install the washer bottle bracket.
49. Install the air deflector.
50. Install the propeller shaft.
51. Install the muffler assembly.





52. Install the master cylinder.





53. Connect the engine harness electrical connector at the longitudinal rail.





54. Notice: Refer to Fastener Notice in Service Precautions.

Install the ground wire and bolt to the longitudinal rail.
^ Tighten the bolt to 10 Nm (89 inch lbs.).
55. Connect the wiring harness to the transmission control module.





56. Connect the engine module wiring harness connectors (1-3) to the underhood electrical center.
57. Connect and lock the I/P electrical connector to the engine at the rear of the left Bank 2 cylinder head.
58. Connect the mass air flow sensor electrical connector.
59. Connect the electrical connector for the brake fluid level switch from the master cylinder.





60. Connect the brake booster vacuum hose (1) to the brake booster (2).
61. Install the radiator support brackets.





62. Connect the purge line (3) to the purge solenoid.
63. Connect the fuel pipe (2) to the fuel rail.
64. Connect the heater hoses to the heater core.
66. Position and secure the surge tank inlet hose to the vehicle.
67. Connect the surge tank inlet hose to the water outlet housing and to the radiator.
68. Connect the outlet hose to the surge tank.
69. Connect the electrical connector for the air conditioning pressure switch and the liquid line to the evaporator.
70. Connect the air conditioning suction hose to the evaporator and install the suction hose bracket to the shock tower.





71. Install the air cleaner duct.





72. Install the cooling fan wiring harnesses (1, 4) to the fan shroud.
73. Install the cooling fan electrical connectors (2, 3).
74. Install the wiper module.
75. Install the battery.
76. Install the fuel injector sight shield.





77. Connect the positive cable to the battery and the underhood electrical center.
78. Connect the negative cable from the battery and the body.





79. Remove J 42640 from the steering column.
80. Fill the cooling system. Refer to Draining and Filling Cooling System (Static Fill) Draining and Filling Cooling System (GE 47719).
81. Charge the air conditioning system. Refer to Refrigerant Recovery and Recharging.
82. Bleed the brake rear circuits. Refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure).