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 .

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. Refer to Lifting and Jacking 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 and brake line to the bundle brackets, the length of the vehicle.
12. Install the rear brake line to the bracket bolt above the rear axle assembly.
13. Connect the EVAP hose to the rear of the fuel filter.
14. Connect the fuel feed line to the fuel filter.
15. Install the brake lines to the bundle clips on the right and left frame rails.





16. Install the transmission assembly.
17. Connect the top heater hose to the water outlet housing.
18. Install the powers steering oil cooler and mounting bracket.
19. Lower the vehicle.
20. Install the radiator, condenser, and transmission oil cooler as an assembly.
21. Install the supercharger charge air cooler radiator assembly.
22. Install the bolt that secures the power steering lines to the radiator.
^ Tighten the bolt to 90 Nm (80 inch lbs.).





23. Connect the center intermediate shaft to the lower intermediate shaft.
24. Install the bolt (3) that secures 2 shafts.
^ Tighten the bolt to 30 Nm (23 ft. lbs.).
25. Working through the left wheelhouse, connect the transmission oil cooler lines near the air conditioning compressor.
26. Working through the right hand wheelhouse, connect the wire harness connector and install the bolt that secures the washer fluid reservoir to the front frame brace.
^ Tighten the bolt to 6 Nm (53 inch lbs.).





27. Install the right and left front wheelhouse liners.
28. Install the right and left wheelhouse splash shields.
29. Install the right and left front tire assemblies.
30. Lower the vehicle.
31. Install the cooling fan.
32. Connect the engine wire harness C5 connector to the inside of the underhood electrical center.
33. Connect both of the chassis electrical connectors at the top of the left shock tower.
34. Install the positive battery cable to the underhood bussed electrical center.
^ Tighten the battery cable nut to 15 Nm (11 ft. lbs.).





35. Install the negative battery cable retainer and bolt to the right hand shock tower.
^ Tighten the retainer bolt to 36 Nm (27 ft. lbs.).
36. Connect the battery current sensor electrical connector.
37. Install the underhood electrical center cover.
38. Connect the underhood fuse block connector C5.
39. Connect the front of the dash electrical connector C102.
40. Connect the charge air cooler reservoir hose to the reservoir.





41. Connect the chassis fuel line (4) to the fuel rail.
42. Install the brake master cylinder.
^ Tighten the retaining nuts to 25 Nm (18 ft. lbs.).
43. Connect the brake fluid level switch.





44. Install the air conditioning liquid and suction lines.
45. Connect the coolant surge tank hose to the radiator.
46. Connect the coolant surge tank hose to the fittings on the water outlet housing.
47. Install the supercharger inlet duct assemblies.





48. Install the air cleaner assembly.
49. Install the fuel injector sight shield.
50. Install the cross vehicle brace.





51. Install the front engine compartment sight shields.
52. Install the positive battery cable.
53. Install the negative battery cable.
54. Remove the J 42640 steering wheel anti-rotation pin.
55. Fill the engine with engine oil. Refer to Engine Oil and Oil Filter Replacement .
56. Fill the cooling system. Refer to Draining and Filling Cooling System (Static Fill) Draining and Filling Cooling System (GE 47719) .
57. Fill the charge air cooling system.
58. Recharge the air conditioning system. Refer to Refrigerant Recovery and Recharging .
59. Bleed the brake system.