Installation

1. Install the engine into the vehicle.
2. Install the front engine mounts bolts and washers to the frame and the engine block.
3. Install the bell housing bolts to the engine.
4. Install the engine mount through bolts.
- Tighten the through mount bolt to 95 Nm (70 ft. lbs.).
5. Install the torque converter to the flywheel.
6. Remove the lifting device, chain and attaching bolt.
7. Install the block heater wiring.
8. Install the flywheel cover.
9. Install the starter assembly.

NOTE: Replace the retaining clips any time the lines are disconnected or connected.

10. Install the transmission cooler lines and the brackets to the engine.
11. Install the wiring harness and the front battery cable clamp at the oil pan.
12. Lower the vehicle.
13. Install the A/C compressor/power steering pump bracket and the line fasteners.
14. Install the injection pump.
15. Install the injection lines.
16. Install the fuel return line.
17. Install the shift cable hold down connection.
18. Install the upper and the lower radiator hoses on the water pump.
19. Install the exhaust manifolds.
20. Install the engine oil fill tube.
21. Install the vacuum pump and the bracket.
22. Install the generator assembly.
23. Install the lower intake manifolds.
24. Install the coolant crossover/thermostat housing and all related hoses.
25. Install the Turbocharger assembly.
26. Replace the O-ring on the turbocharger before installing the upper intake manifold.
27. Install the upper intake manifold.
23. Install the electrical harness and all the, connectors and the brackets.
29. Install the EGR/Boost solenoids and glow plug controller.
30. Install the engine cooling fan.
31. Install the radiator support assembly using the following components:
- Two ground straps
- Headlight assemblies
- Radiator
- A/C condenser if equipped
32. Connect the radiator hoses.
33. Install the power steering reservoir hose.
34. Ensure the power steering fluid is at the proper level.
35. Install the grille assembly.
36. Install the coolant recovery reservoir.
37. Install the front bumper.
38. Install the air cleaner assembly and the air intake duct.
39. Install the engine cover
40. Install the battery.
- Fill the cooling system with the proper quantity and the grade of the coolant.
- Change the engine oil and oil filter.
- Recharge the A/C system.