Installation

INSTALLATION

CAUTION: When installing the engine into a vehicle equipped with an automatic transmission, be careful not to damage the trigger wheel on the flywheel.

1. Attach a lifting device to the engine and lower the engine into the engine compartment. For easier installation, it may be necessary to remove the engine mount cushions from the engine mount bracket as an aide in alignment of the engine to the transmission.
2. Vehicles with Manual Transmission:
a. Insert the transmission shaft into the clutch spline.
b. Align the flywheel housing with the engine.
c. Install and tighten the flywheel housing lower bolts finger tight.

3. Vehicles with Automatic Transmission:
a. Align the transmission torque converter housing with the engine.
b. Loosely install the converter housing lower bolts and install the next higher bolt and nut on each side.
c. Tighten all 4 bolts finger tight.

Fig. 6 Front Mounts - XJ Vehicles:

4. Install the engine mount cushions (if removed).
5. Lower the engine and engine mount cushions onto the engine compartment brackets. Install the bolts and finger tighten the nuts.
6. Remove the engine lifting device.
7. Raise and support the vehicle.
8. Install the remaining flywheel and converter housing bolts. Tighten all bolts to 38 Nm (28 ft. lbs.) torque.
9. Vehicles with Automatic Transmission:
a. Install the converter-to-drive plate bolts.
b. Ensure the installation reference marks are aligned.

10. Install the flywheel and converter housing access cover.
11. Install the exhaust pipe support and tighten the screw.
12. Tighten the engine mount-to-bracket bolts.
13. Connect the engine speed sensor wire connections and tighten the screws.
14. Connect the exhaust pipe to the manifold.
15. Install the starter motor and connect the cable.
16. Connect the wires to the starter motor solenoid.
17. Lower the vehicle.
18. Connect all the vacuum hoses and wire connectors identified during engine removal.
19. If equipped with power steering:
a. Remove the protective caps.
b. Connect the hoses to the fittings at the steering gear. Tighten the nut to 52 Nm (38 ft. lbs.) torque.
c. Fill the pump reservoir with fluid.

20. Install the power brake vacuum check valve to the booster, if equipped.

Fig. 15 Accelerator Cable, Speed Control Cable, Automatic Transmission Control Cable & Quick-Connect Fuel Lines:

21. Connect the fuel inlet and return hoses at the fuel rail. Verify that the quick - connect fitting assembly fits securely over the fuel lines by giving the fuel lines a firm tug.
22. Install the fuel line bracket to the intake manifold.
23. Connect the distributor electrical connector and oil pressure switch connector.
24. Connect the injection system wire harness connector on the dash panel.
25. Connect the line pressure cable (if equipped with automatic transmission).
26. Connect the speed control cable, if equipped.
27. Connect the throttle cable linkages.
28. Connect the heater hoses at the engine thermostat housing and water pump.
29. Install the fan assembly to the idler pulley.
30. Install the radiator or radiator and condenser (if equipped with A/C).
31. Connect the service valves to the A/C compressor ports, if equipped with A/C.
32. Charge the air conditioner system.
33. Connect radiator fan switch wire.
34. Connect automatic transmission fluid cooler lines, if equipped.
35. Install the fan shroud, electric cooling fan and radiator and condenser (if equipped with A/C).
36. Install upper radiator support.

Fig. 13 Upper Radiator Hose, Coolant Recovery Hose, Fan Shroud & Heater Hoses:

37. Connect the upper radiator hose.
38. Connect the lower radiator hose.
39. Fill the cooling system with reusable coolant and/or new coolant.
40. Align the hood to the scribe marks. Install the hood.
41. Connect the vacuum harness connector.
a. Firmly push the connectors together ensuring that the retaining tabs are engaged.
b. Insert the vacuum connector assembly into the retaining bracket on the intake manifold.

Fig. 16 Air Cleaner Assembly & Power Steering Pump:

42. Install the air cleaner assembly.
43. Install the battery and connect the battery cable.

WARNING: Use extreme caution when the engine is operating. DO NOT stand in a direct line with the fan. DO NOT put your hand near the pulleys, belts or fan. DO NOT wear loose clothing.

44. Start the engine, inspect for leaks and correct the fluid levels, as necessary.