Engine - Installation

INSTALLATION

Special Tools:






CAUTION:
If the original engine has experienced a catastrophic failure or an individual failure with the piston, cylinder bore, engine block, valve or valve seat, the intake manifold MUST be replaced with a new manifold.





1. Position engine in the vehicle.

2. Position both the left and right side engine mount brackets and install the through bolts and nuts. Tighten nuts to 4X2 vehicles95 Nm (70 ft. lbs.). 4X4 vehicles102 Nm (75 ft. lbs.).

3. 4X4 vehiclesInstall locknuts onto the engine mount brackets. Tighten locknuts to 41 Nm (30 ft. lbs.).

4. Remove jack from under the transmission.

5. Remove Engine Lifting Fixture (10101) (1).





6. Connect right (1) side ground straps.





7. Connect left (1) side ground straps.

8. Install intake manifold.

9. Position generator wiring behind the oil dipstick tube, then install the oil dipstick tube upper mounting bolt.

10. Install power steering pump.

11. Connect fuel supply line quick connect fitting Service and Repair.





12. Install generator Service and Repair

13. Install A/C condenser A/C Condenser - Installation

14. Install radiator Engine Cooling Radiator - Installation and transmission oil cooler.

15. Connect radiator upper and lower hoses.

16. Connect the transmission oil cooler lines to the radiator.

17. Install accessory drive belt, fan assembly and shroud.





18. Install A/C compressor (2) Service and Repair

19. Install throttle body resonator assembly and air inlet hose. Tighten clamps 4 Nm (35 in. lbs.).

20. Raise vehicle.





21. Install transmission to engine mounting bolts. Tighten the bolts to 41 Nm (30 ft. lbs.).

22. Install torque converter bolts (Automatic Transmission Only).

23. Connect crankshaft position sensor (1).





24. 4X4 vehiclesPosition and install the axle isolator bracket onto the axle, transmission and engine block. Tighten bolts to specification Specifications.

25. Install starter (4) Service and Repair.





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

26. Install structural cover .





27. Install exhaust crossover pipe (5).

28. Install engine block heater power cable, If equipped.

29. 4X4 vehiclesConnect axle vent tube to left side engine mount.

30. Lower vehicle.

31. Fill engine with clean oil.

32. Recharge the A/C system Service and Repair.

33. Refill the engine cooling system Service and Repair.

34. Connect the battery positive and negative cables.

35. Start the engine and check for leaks.