Installation
Engine-Pickup Chassis
Special Tool(s)
Installation
All vehicles
1. Attach the Modular Engine Lift Bracket.
2. Remove the engine from the engine stand.
3. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the aluminum retainer plate. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
Clean and inspect the mating surfaces of the cylinder block and the retainer plate.
4. NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply a bead of silicone gasket and sealant around the rear oil seal retainer sealing surface.
5. Install the retainer plate. Tighten the bolts in two stages.
^ Stage 1: Tighten the retainer plate bolts to 10 Nm (89 inch lbs.), in the sequence shown.
^ Stage 2: Tighten the oil pan bolts to 20 Nm (20 ft. lbs.), then tighten an additional 90 degrees.
6. Use the two crankshaft rear oil seal installers to install the crankshaft rear oil seal.
7. Using the two crankshaft rear oil seal installers and the crankshaft rear oil slinger installer, install the crankshaft rear oil slinger.
8. Install the flywheel.
9. Position the engine in the vehicle and remove the Modular Engine Lift Bracket and the jack supporting the transmission.
10. Install and tighten the nuts.
11. On automatic transmission equipped vehicles, install the transmission oil level indicator tube and the ground strap on all vehicles.
12. Install the heater water tube and the two studs.
13. Raise and support the vehicle.
Automatic transmission vehicles
14. Install the lower transmission to engine bolts.
15. Install the access plug.
16. Install and tighten the four new nuts retaining the torque converter.
17. Install the flywheel inspection cover.
All vehicles
18. Install the wiring bracket.
Automatic transmission vehicles
19. Install the starter motor.
All vehicles
20. Install the oil cooler to the oil filter adapter and install the oil bypass filter.
Manual transmission vehicles
21. Install the clutch and transmission.
All vehicles
22. Install and tighten the nuts.
23. Install the ground strap.
Automatic transmission vehicles
24. Install the transmission cooler line bracket.
All vehicles
25. Install the A/C compressor.
26. Lower the vehicle.
Automatic transmission vehicles
27. Install the remaining transmission-to-engine bolts and fuel line bracket.
All vehicles
28. Connect the transmission wiring harness and the LH and RH heated exhaust gas oxygen sensor connectors.
29. Connect the heater hose.
30. Install the suction line to the accumulator.
31. Connect the A/C cycling switch.
32. Connect the connector and position the harness aside.
33. Install the power steering pump.
34. Install the intake manifold.
35. Install the harness mounting bracket and connect the 42-pin and 16-pin connectors.
36. Install the radiator.
37. Install the A/C condenser core.
38. Install the radiator grille support.
39. Fill all fluids to the correct levels.
40. Connect the battery ground cable.
41. Start the engine and check for leaks. Stop the engine and recheck the fluid levels.
42. Evacuate and recharge the A/C system.