Installation
Installation Procedure1. Remove the J 21366 from the transmission.
2. Install an engine hoist to the J 41798.
3. Remove the engine from the engine stand.
4. Install the engine.
5. Mate the engine to the transmission.
6. Remove the floor jack from under the transmission for support.
Notice: Refer to Fastener Notice in Service Precautions.
7. Install the 3 upper transmission bolts/studs.
^ Tighten the bolts/studs to 50 Nm (37 ft. lbs.).
8. Raise the vehicle.
9. Install the lower transmission bolt/studs.
^ Tighten the bolts/studs to 50 Nm (37 ft. lbs.).
10. Install the transmission bolt and stud on the right side.
^ Tighten the bolts/studs to 50 Nm (37 ft. lbs.).
11. Install the transmission oil level indicator tube.
12. Install the transmission oil level indicator tube nut.
^ Tighten the nut to 10 Nm (89 ft. lbs.).
13. Install the torque converter bolts.
^ Tighten the bolts to 60 Nm (44 ft. lbs.).
14. Install the 3 frame engine mount bracket bolts to both the right and left sides.
^ Tighten the bolts to 50 Nm (37 ft. lbs.).
15. Install the catalytic converter.
16. Lower the vehicle.
17. Remove the J 41798 from the cylinder heads.
18. Install the ignition coil(s) (as required).
^ Tighten the bolts to 8 Nm (71 inch lbs.).
19. Install the auxiliary heater inlet and outlet hoses/pipes to the water pump.
20. Using J 38185, reposition the auxiliary heater inlet and outlet hose clamps.
21. Connect the auxiliary heater inlet and outlet hose/pipe assembly to the heater water shutoff valve pipes.
22. Install the outlet hose to the water outlet.
23. Using J 38185, reposition the inlet hose clamp.
24. Install the inlet hose to the water outlet.
25. Using J 38185, reposition the inlet hose clamp.
26. Position the bracket with generator to the engine.
27. Install the generator bracket bolts.
^ Tighten the bolts to 50 Nm (37 ft. lbs.).
28. Install the generator cable to the generator, perform the following:
^ Install the generator cable.
^ Install the generator cable nut to the terminal stud.
^ Tighten the nut to 9 Nm (80 inch lbs.).
^ Slide the boot down covering the terminal stud.
29. Gather all branches of the engine wiring harness and position the harness over the engine.
30. Raise the vehicle.
31. Connect the A/C compressor electrical connector.
32. Install the battery cable channel to the oil pan.
33. Install the battery cable channel bolt.
^ Tighten the bolt to 12 Nm (106 inch lbs.).
34. Install the starter.
35. Install the ground terminal bolts (2, 4).
^ Tighten the bolt to 25 Nm (18 ft. lbs.).
36. Lower the vehicle.
37. Install the retaining clip (1) to the cylinder head.
38. Connect the A/C pressure switch electrical connector (2).
39. Install the retaining clips to the brackets.
40. Install the ground terminal bolt (2).
^ Tighten the bolt to 25 Nm (18 ft. lbs.).
41. Connect the ECT sensor (1).
42. Install the rear auxiliary A/C compressor pipe nut and bolt (2, 5).
^ Tighten the nut/bolt to 20 Nm (15 ft. lbs.).
43. Connect the rear auxiliary A/C compressor pipe fitting (7).
^ Tighten the nut to 16 Nm (12 ft. lbs).
44. Install the A/C compressor hose.
45. Connect the following electrical connectors:
^ Oil pressure sensor (1)
^ Oxygen sensors (2, 3)
^ Camshaft position (CMP) sensor (4)
46. Install the intake manifold.
47. Install the wheel drive shafts.
48. Install the front differential drive axle, if equipped with 4WD.
49. Install the radiator support brace.
50. Install the radiator.
51. Recharge the refrigerant.
52. Connect the negative battery cable.
53. Remove the fender covers from both fenders.
54. Prelube the engine.
55. Perform the CKP system variation learn procedure.
56. Install the hood.
Important: After an overhaul, the engine should be tested. Use the following procedure after the engine is installed in the vehicle.
57. Test the vehicle using the following procedure:
^ Disable the ignition system.
^ Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
^ Enable the ignition system.
^ Start the engine and listen for unusual noises.
^ Check the vehicle oil pressure gauge or light and confirm that the engine has acceptable oil pressure.
^ Run the engine speed at about 1000 RPM until the engine has reached normal operating temperature.
^ Listen for sticking lifter and other unusual noises.
^ Inspect for fuel, oil and/or coolant leaks while the engine is running.
^ Close the hood.