Installation Procedure

Installation Procedure





1. Install the J 36857 (1) to the rear of the left cylinder head with a suitable bolt.





2. Install the J 36857 (1) to the front of the right cylinder head with a suitable bolt.
3. Install a suitable lifting device. The engine will have to be angled in order to install. Use a load positioning sling to assist in angling the engine.
4. Remove the engine from the stand.
5. Install the following:
^ Refer to Engine Flywheel Installation (Automatic Transmission) Engine Flywheel Installation (Manual Transmission).
^ Refer to Exhaust Outlet Installation.
^ Refer to Upper Oil Pan Installation.
^ Refer to Engine Flywheel Housing Installation.
6. Install the engine in the vehicle.

7. Important: Do not draw the engine to the transmission using the transmission bolts. If everything is aligned properly the engine and transmission will come together.

Loosely install 2 transmission to engine bolts.





8. Notice: Refer to Fastener Notice in Service Precautions.

Install the left and right side engine mount frame brackets.
Tighten the through-bolts to 75 Nm (55 ft. lbs.).





9. Install the engine mount to frame bracket bolts (left side shown).
Tighten the bolts to 65 Nm (50 ft. lbs.).
10. Remove the J 36857 from the cylinder heads.
11. Raise the vehicle.





12. Install the transmission to engine bolts (automatic transmission shown).
Tighten the studs and bolts to 50 Nm (37 ft. lbs.).





13. If equipped with an automatic transmission install the torque convertor bolts.
Tighten the bolts to 60 Nm (44 ft. lbs.).





14. If equipped with an automatic transmission, install the nuts retaining the transmission fluid fill tube bracket.
Tighten the nuts to 18 Nm (13 ft. lbs.).
15. If the vehicle is 4WD, install the lower oil pan. Refer to Lower Oil Pan Replacement.





16. If equipped with an automatic transmission, install the nut retaining the transmission oil cooler line clip.
Tighten the nut to 9 Nm (80 inch lbs.).





17. Install the exhaust pipe to the exhaust outlet.
18. Install the exhaust manifold pipe to the exhaust outlet clamp.
Tighten the clamp to 40 Nm (30 ft. lbs.).
19. Lower the vehicle to work through the front fender wheelhouse openings.





20. Install the bolt retaining the battery negative cable and the engine wiring harness ground wire to the left side of the engine.
Tighten the bolt to 34 Nm (25 ft. lbs.).





21. Install the bolts holding the battery cable channel retainer to the lower crankcase.
Tighten the bolts to 12 Nm (106 ft. lbs.).





22. Install the bolts holding the auxiliary battery negative cable and the engine wiring harness ground wires to the right side of the engine.
Tighten the bolts to 34 Nm (25 ft. lbs.).





23. Install the nut holding the battery cable bracket to the right side of the lower crankcase.
Tighten the nut to 8 Nm (71 inch lbs.).
24. Install the starter.





25. Connect the cord for the engine coolant heater.





26. Install the engine oil pan skid plate.
Tighten the oil pan skid plate bolts to 20 Nm (15 ft. lbs.).





27. Install the engine shield.
Tighten the bolts to 20 Nm (15 ft. lbs.).
28. Lower the vehicle.
29. Install the bolt and the ground wires at the rear of the left cylinder head.
Tighten the bolt to 34 Nm (25 ft. lbs.).





30. Install the generator mounting bracket and bolts.
Tighten the bolts to 50 Nm (37 ft. lbs.).





31. Install the right idler pulley and bolt (1).
Tighten the bolt to 43 Nm (32 ft. lbs.).
32. Install the air conditioning compressor and the power steering pump mounting bracket.





33. Position the engine wiring harness on the engine.
34. Position the A/C compressor.
35. Install the A/C compressor mounting bolts.
Tighten the bolts to 50 Nm (37 ft. lbs.).
36. Install the A/C suction hose to the accumulator.
37. Install the drive belt.





38. Connect the fuel hoses at the engine.
39. Install the nut and the fuel hose bracket to the valve rocker arm cover stud.
Tighten the nut to 21 Nm (15 ft. lbs.).





40. Connect the main engine electrical harness connectors.
41. Push down on the latches (1) in order the connect the connectors.
42. Close the harness clip (2).





43. Install the cable junction block and bolt (1) to the power steering pump.
Tighten the bolt to 9 Nm (80 inch lbs.).
44. If equipped, install the battery cable to the auxiliary generator.
45. Install the battery cable to the generator.
Tighten the nut to 9 Nm (80 inch lbs.).
46. Install the battery cable harness clip to the bracket.





47. Connect the following electrical connectors:
^ Generator connector (1)
^ A/C refrigerant switch (2)
^ Dual generator harness connector (3), if equipped
^ A/C compressor clutch (4)
48. Install the harness clip to the A/C compressor bracket.
49. Install the upper radiator support.
50. Install the A/C condenser.
51. Install the charged air cooler.
52. Install the radiator.





53. Install the outlet radiator hose to the radiator and tighten the hose clamp.
54. Install the hose clips to the frame.





55. Install the outlet radiator hose to the engine and tighten the hose clamp.
56. Install the lower fan shroud.
57. Install the upper fan shroud.





58. Connect the inlet heater hose (1) to the heater core inlet. Firmly push to quick connector onto the heater core pipe until you hear an audible click.
59. Install the outlet heater hose to the outlet radiator hose.
60. Install the bolt retaining the heater hose pipe to the bracket.
Tighten the bolt to 25 Nm (18 ft. lbs.).





61. Install the outlet radiator hose to the radiator and the engine and tighten the hose clamps.
62. Install the charged air cooler pipes and hoses to the turbocharger and the charged air cooler.
63. Install both fender wheelhouse inner panels (1).
64. Install both front tires and wheels.
65. Install the surge tank.
66. Install the air cleaner.





67. Connect the following engine wire harness connectors:
^ Mass air flow switch (1)
^ Air continuation pressure cycling switch (2)
^ Surge tank switch (6)
68. Install the engine wire harness clip to the accumulator (3).
69. Install the engine wire harness clips to the wheelhouse inner panel (4).
70. Install the engine wire harness clip to the engine bracket (5).
71. Connect the batteries negative cables.
72. Fill the engine coolant. Refer to Draining and Filling Cooling System (Static Fill) Draining and Filling Cooling System (w/RPO HP2) Draining and Filling Cooling System (Vac-N-Fill).
73. Prelube the engine. Refer to Engine Prelubing.
74. Operate the engine, inspect for coolant, oil, fuel, and exhaust leaks.
75. Inspect for proper oil pressure.
76. Inspect for proper engine operation.





77. Position the hood in the normal operating position by moving the hood hinge bolts from service position (2) to normal operating position (1).
Tighten the bolts to 25 Nm (18 ft. lbs.).
78. Road test the vehicle for normal operation.
79. Inspect for coolant, oil, or exhaust leaks.