Engine Installation
NOTE: If you install a new engine, make sure any remaining components, brackets, or accessories are transferred to the new engine.
1. Install the engine into the frame.
2. Connect the engine to the transmission.
3. Remove the transmission jack.
4. Lower the engine and the transmission onto the engine mountings.
5. Install the engine mount through-bolts.
^ Tighten the engine mount through-bolts to 100 Nm (74 ft. lbs.).
6. Install the exhaust "Y" pipe to the exhaust manifolds.
7. Connect the fuel line bracket to the rear of the left cylinder head.
8. Connect the fuel lines to the fuel rail.
9. Connect the electrical harness at the transmission connections and all emissions sensors.
10. Connect the transfer case to the engine block support brace.
11. Remove the J 41427 from the engine.
12. Install the intake manifold bolts where the lift brackets were.
13. Connect the air conditioning compressor, the bracket, and the accessory drive bracket (if equipped).
14. Connect the EGR pipe to the intake manifold.
NOTE: Align the frame using the two alignment holes in the frame and the body. Use a pry bar or dowel pin in order to align the holes as the vehicle is being lowered/raised into the frame.
15. Lower the vehicle onto the frame (side post hoist). Raise the engine/frame assembly up into the vehicle (twin post hoist).
NOTE: The six frame mounting bolts must be tightened in sequence in order to ensure proper alignment of the frame to the chassis.
16. Install the frame bolts
a. Tighten the frame mounting bolts using the following sequence:
b. Tighten the right center bolt first to 155 Nm (114 ft. lbs.).
c. Tighten the left center bolt second to 155 Nm (114 ft. lbs.).
d. Tighten the right front bolt third to 90 Nm (66 ft. lbs.).
e. Tighten the left rear bolt fourth to 90 Nm (66 ft. lbs.).
f. Tighten the left front bolt fifth to 90 Nm (66 ft. lbs.).
g. Tighten the right rear bolt last to 90 Nm (66 ft. lbs.).
17. Remove the J41602 from the pinch weld flange.
18. Lower the vehicle (twin post hoist).
19. Connect the engine wire harness connectors.
20. Connect the wheel housing splash shields to the frame.
21. Connect the steering shaft to the steering gear.
22. Connect the cooler line to the steering pump.
23. Connect the cooler line to the steering gear.
24. Connect the lines to the hydro boost unit.
25. Connect the hose to the power steering reservoir.
26. Connect the heater hoses to the engine.
27. Connect the SIR sensor connector.
28. Connect the cruise control stepper motor connector.
29. Connect the throttle cable.
30. Connect the air conditioning lines at the accumulator and the condenser (if equipped).
31. Connect the distributor cap and the spark plug wires.
32. Install the radiator.
33. Install the air filter assembly.
34. Connect the transmission oil cooler lines to the radiator.
35. Replace the retaining clips.
36. Connect the engine oil cooler lines to the radiator.
37. Replace the retaining clips.
38. Connect the master cylinder.
39. Raise the vehicle.
40. Connect the rear brake line to the BMPV. .
41. Connect the park brake bracket to the frame.
42. Connect the fuel lines at the fuel filter.
43. Connect the rear air conditioning lines at the rear crossmember (if equipped).
44. Install the transfer case vent tube.
45. Connect the power steering cooler.
46. Install the front bumper.
47. Connect the shift linkage to the transmission.
48. Install the torque converter bolts.
49. Install the starter shield and the starter.
50. Install the rear propeller shaft.
51. Install the exhaust system at the center flange behind the catalytic converter.
52. Lower the vehicle.
53. Fill the crankcase with the proper grade of engine oil.
54. Recharge the air conditioning system (if equipped).
55. Fill and bleed the brake system.
56. Fill the transmission with the proper grade and quantity of transmission fluid.
57. Fill the power steering system with the proper grade and quantity of power steering fluid.
58. Fill the cooling system with the proper grade of engine coolant.
59. Install the engine cover.
60. Install the battery.