Installation Procedure

Installation Procedure
1. Install the engine to the front frame.
2. Ensure that all the hoses, wires, pipes and shock modules are positioned out of the way to avoid contact during engine installation.
3. With the aid of an assistant, raise the table and/or lower the vehicle to install the engine, front frame, fuel/brake bundle and front suspension.

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

Install the frame bolts.
^ Tighten the frame bolts to 191 Nm (141 ft. lbs.).
5. Install the right and left upper shock modules bolts.
^ Tighten the bolts to 112 Nm (83 ft. lbs.).
6. If the vehicle is equipped with Magnaride, connect the shock module electrical connectors.
7. Connect the heater inlet hose to the water housing.
8. Connect the heater outlet hose to the outlet pipe.
9. Raise the vehicle.
10. Install the fuel and brake line bundle bracket to the right side wheelhouse.
^ Tighten the bracket bolt to 90 Nm (80 inch lbs.).
11. Install the fuel filter bracket bolt.
^ Tighten the bracket bolt to 90 Nm (80 inch lbs.).
12. Install the fuel and brake line to the bundle brackets, the length of the vehicle.
13. Install the rear brake line to the bracket bolt above the rear axle assembly.
^ Tighten the bracket bolt to 90 Nm (80 inch lbs.).
14. Connect the EVAP hose to the rear of the fuel filter.
15. Connect the fuel line to the fuel filter.
16. Install the brake lines to the bundle clips on the right and left frame rails.
17. Install the transmission assembly.
18. Install the transfer case, if equipped.
19. Install the powers steering oil cooler to the mounting bracket.
20. Lower the vehicle.
21. Install the radiator, condenser and transmission oil cooler as an assembly.
22. Raise the vehicle.
23. Install the bolt that secures the power steering to the radiator.
^ Tighten the bolt to 90 Nm (80 inch lbs.).





24. Connect the center intermediate shaft to the lower intermediate shaft.
^ Tighten the bolt to 30 Nm (23 ft. lbs.).
25. Install the bolt (3) that secures 2 shafts.
26. Working through the left wheelhouse, connect the transmission oil cooler lines near the air conditioning compressor.
27. Working through the right hand wheelhouse, install the bolt which secures the washer fluid reservoir to the front frame brace.
^ Tighten the bolt to 6 Nm (53 inch lbs.).
28. Install the right and left front wheelhouse liners.
29. Install the right and left wheelhouse splash shields.
30. Install the right and left front tire assemblies.
31. Lower the vehicle.
32. Install the cooling fan.
^ Cooling Fan Replacement - Electric (LH2 Standard Cooling) Cooling Fan Replacement - Electric (LH2 Heavy Duty Cooling) Cooling Fan Replacement - Electric (LY7)
33. Connect the electrical connector C113 at the right hand frame rail.
34. Connect the electrical connector C5 to the underhood bussed electrical center.
35. Connect the transmission control module.
36. Connect the chassis electrical connector located at the top of the right hand shock tower.
37. Install the positive battery cable to the underhood bussed electrical center.
^ Tighten the battery cable nut to 15 Nm (11 ft. lbs.).
38. Install the negative battery cable retainer and bolt to the right hand shock tower.
^ Tighten the retainer bolt to 36 Nm (27 ft. lbs.).
39. Install the underhood electrical center cover.
40. Connect the underhood fuse block connector C5.
41. Connect the front of the dash electrical connector C102.
42. Install the fuel line retainer located on the bracket attached to the heater lines on the front of the dash.
43. Install the brake master cylinder.
^ Tighten the retaining nuts to 25 Nm (18 ft. lbs.).
44. Connect the brake fluid level switch.
45. Connect the brake booster vacuum line to the brake booster.
46. Install the air conditioning liquid line to the condenser.





47. Install the air conditioning suction hose located at the top of the left hand shock tower.
48. Install the air conditioning liquid and suction lines to the retaining feature (1) on the fan shroud.
49. Connect the coolant surge tank hose to the radiator.





50. Install the air cleaner assembly.
51. Install the fuel injector sight shield.
52. Install the cross vehicle brace.
53. Install the positive battery cable.
54. Install the negative battery cable.
55. Remove J 42640 .
56. Fill the engine with engine oil. Refer to Engine Oil and Oil Filter Replacement .
57. Fill the cooling system. Refer to Draining and Filling Cooling System (Static Fill) Draining and Filling Cooling System (GE 47719).
58. Recharge the air conditioning system. Refer to Refrigerant Recovery and Recharging.
59. Bleed the brake system. Refer to Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Pressure).