Installation

Special Tool(s)





Material

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 flexplate.
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. Install the heater tube and the two studs.





12. Install the transmission oil level indicator tube and the ground strap on all vehicles.
13. Raise and support the vehicle.





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.





18. Install the wiring bracket.
19. Install the starter motor.

All vehicles





20. CAUTION: A new oil cooler must be installed or severe damage to the engine can occur.

Connect the coolant hoses to the new oil cooler.





21. Position a new oil cooler and install the threaded insert.





22. Install the oil filter.





23. Install and tighten the nuts.





24. Install the ground strap.





25. Install the transmission cooler tube bracket.





26. Position and install the heater hose at the rear of the engine.





27. Install the remaining transmission-to-engine bolts and fuel line bracket.





28. Connect the transmission wiring harness and the LH and RH Heated Exhaust Gas Oxygen (HEGO) sensor connectors.

Vehicles equipped with A/C





29. Install the suction line to the accumulator.





30. Connect the A/C cycling switch.





31. Connect the connector and position the harness aside.
32. Install the A/C compressor.

All vehicles





33. Install the power steering pump.





34. Position and connect the lower radiator hose at the oil cooler inlet.
35. Install the intake manifold.





36. Install the harness mounting bracket and connect the 42-pin and 16-pin connectors.
37. Install the radiator.

Vehicles equipped with A/C
38. Install the A/C condenser core.

All vehicles
39. Install the radiator grille support.
40. Fill all fluids to the correct levels.
41. Connect the battery ground cable.
42. Start the engine and check for leaks. Stop the engine and recheck the fluid levels.

Vehicles equipped with A/C
43. Evacuate and recharge the A/C system.