Installation

Engine

Service Repair No - 12.41.01.9

Installation
1. Remove the torque converter retainer.
2. Install the engine.
^ Connect the lifting chains.
^ Carefully lower the engine until approximately 35mm above engine mounts.
^ With assistance align the engine to the transmission and engine mounts.
3. Install the transmission retaining bolts.
^ Clean the component mating faces.
^ Tighten the bolts to 45 Nm (33 ft. lbs.).
4. Tighten the engine mount nuts to 90 Nm (66 ft. lbs.).
5. Remove the engine lifting bracket.
^ Disconnect the lifting chains.
^ Remove the 7 bolts.
^ Remove the 12 nuts.
6. Attach the flexplate to the torque converter.
^ Rotate the crankshaft to access the retaining bolts.
^ Tighten the bolts to 45 Nm (33 ft. lbs.).
7. Install the CKP sensor.
^ Clean the component mating faces.
^ Tighten the bolt to 8 Nm (6 ft. lbs.)
8. Install the engine wiring harness support bracket.
9. Install the steering column lower universal joint assembly.
^ Install new patch lock bolts and tighten to 25 Nm (18 ft. lbs.).
10. Position the RH catalytic converter to the exhaust manifold.
^ Clean the components.
^ Tighten the new bolts to 22 Nm (16 ft. lbs.).





11. CAUTION: Make sure there is a clearance (A) of 25 mm to 30 mm between the closest points of the LH catalytic converter and the front driveshaft.

Position the LH catalytic converter to the exhaust manifold. Clean the components.
^ Tighten the new bolts to 22 Nm (16 ft. lbs.).
12. Connect the engine oil cooler hoses.
^ Secure with the clips.
13. Connect the coolant pump hoses.
^ Secure with the clips.
14. Install the cylinder head coolant flange.
^ Clean the component mating faces.
^ Install a new O-ring seal.
^ Tighten the bolts to 10 Nm (7 ft. lbs.).
15. Connect the ECT sensor electrical connector.
16. Connect the engine oil temperature sensor electrical connector.
17. Install the EGR pipe.
^ Clean the component mating faces.
^ Install to the exhaust manifold, but do not fully tighten the union nut at this stage.
18. Install the transmission cooler pipes.
^ Install the support bracket.
^ Tighten the nut to 10 Nm (7 ft. lbs.).
19. Connect the engine ground cable, make sure the mating faces are clean.
^ Tighten the nut to 25 Nm (18 ft. lbs.).
^ Install the cover.
20. Install the starter motor.
^ Clean the component mating faces.
^ Connect the electrical connectors.
^ Tighten the nut to 10 Nm (7 ft. lbs.). Install the terminal nut insulator. Install the terminal cover. Tighten the bolts to 45 Nm (33 ft. lbs.).
21. Install the A/C compressor mounting bracket assembly.
^ Clean the component mating faces.
^ Tighten the bolts to 45 Nm (33 ft. lbs.).
^ Install the KS electrical connector clip.
^ Connect the A/C compressor electrical connection.
22. Install the generator mounting bracket.
^ Clean the component mating faces.
^ Tighten the bolts to 45 Nm (33 ft. lbs.).
^ Secure the clip.
23. Connect the generator electrical connectors.
^ Tighten the nut to 10 Nm (7 ft. lbs.).
^ Install the cover.
^ Connect and secure the electrical connector.
24. Install the accessory drive belt.
25. Install the cooling fan lower shroud.
^ Position and secure in the clips.
26. Install the wiring harness to the plenum.
^ Secure with the clips.
27. Connect the ECM electrical connectors.
28. Install the four-wheel drive control module.
29. Install the fuel rail.
30. Fill the engine with oil.
31. Install the air cleaner assembly.
32. Refill and bleed the cooling system.
33. Return the hood from the service position.
^ Release the 2 clips.
^ Connect the struts and secure with the clips.
34. Connect the battery ground cable.