Installation

Special Tool(s)





Material

Installation
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.





2. Raise the engine high enough to clear the No. 1 crossmember, then position the engine into the vehicle.





3. Align the torque converter studs with the holes in the engine flywheel, then lower the engine onto the engine mount towers.
4. Remove the heavy duty floor crane and the diesel engine lifting bracket.
5. Remove the transmission jack.





6. Install the transmission-to-engine mounting bolts.





7. Install the new torque converter-to-flywheel retaining nuts.





8. Install the flywheel housing cover.





9. NOTE: LH shown, RH similar.

Install the LH and RH side engine mount retaining nuts.





10. Remove the engine lifting eye from the right side cylinder head.





11. Install the manufacturer's lifting bracket.





12. Remove the two engine lift adapters.





13. Install the transmission cooler tube bracket and nut.
14. Position the starter wiring and block heater cord.





15. Install the left rear valve cover stud.





16. Position the turbocharger adapter pipe.





17. NOTE: Apply anti-seize lubricant to the threads prior to installing the bolts.

NOTE: LH side shown, RH side similar.

Loosely install the bolts for the turbocharger adapter pipe.





18. Connect the starter wiring and install the solenoid cap.





19. Connect the block heater electrical connector.





20. Connect the ground strap on the right head and install the bolt.





21. Install the automatic transmission fluid indicator and tube.





22. Position the engine wiring harness back. Connect the Crankshaft Position (CKP) sensor electrical connector and wiring retainers.

Vehicles with A/C





23. Install the A/C compressor.





24. Remove the caps or plugs and install a new O-ring seal. Install the A/C hose and retaining nut.





25. Connect the A/C high pressure switch and the clutch electrical connectors.

All vehicles





26. Connect the RH glow plug electrical connector.





27. Connect the wiring retainers to the studs.





28. Connect the Injection Control Pressure (ICP) sensor electrical connector.





29. Install the glow plug mounting bracket and the nuts.





30. Connect the wire retainers.





31. Connect the glow plug module electrical connectors. Connect the push pin retainer and the Injection Control Pressure (ICP) sensor electrical connector.





32. Connect the ground cable and the ground stud.





33. Install the battery cable bracket and the nut.





34. NOTE: The lower bolts need to be installed evenly.

Position the power steering pump and install the lower bolts.





35. Install the power steering pump upper bolts.





36. NOTE: Only one stand-off shown.

Install the stator stand offs.





37. Connect the fuel lines and install the clips.





38. Connect the heater hose at the front cover.





39. Install the lower radiator hose.





40. Connect the LH glow plug connector.





41. Position the engine wiring harness and connect the Camshaft Position (CMP) sensor.





42. Connect the 12-pin and 8-pin electrical connectors.





43. Connect the Powertrain Control Module (PCM) electrical connector.





44. Install the battery tray and bolts.





45. Install the fuel injection control module mounting brackets and retaining nuts.





46. Position the turbocharger outlet pipe.
47. Install the intake manifold.





48. NOTE: LH shown, RH similar.

NOTE: Alternately tighten the bolts to specifications.

Tighten the turbocharger adapter pipe at the flanges.





49. Tighten the nuts at the turbocharger adapter pipe flange.





50. Install the transmission oil cooler and bolts.





51. Connect the transmission oil cooler hoses.





52. Position and install the power steering cooler and bolts.
53. Install the bumper.
^ Install the front bolts (two each side).
^ Install the rear supporting bolts (one each side).





54. Install the upper radiator support and bolts.





55. Position the body feed cable and install the retaining nut.
56. Install the radiator grille opening panel reinforcement.

Vehicles with A/C
57. Install the A/C condenser assembly.

All vehicles
58. Install the charge air cooler and the air cleaner assembly.
59. Install the radiator.
60. Connect the LH and RH battery cables.
61. Fill the motor with clean engine oil.
62. Check and fill the automatic transmission.
63. Cycle the key 3 times prior to starting the vehicle to avoid the possibility of air lock in the fuel system.