Installation
1. Install exhaust manifold gasket and exhaust manifold. Tighten exhaust manifold bolts to 20-30 N-m (15-22 lb-ft) in sequence.
2. Install EGR valve to exhaust manifold tube.
3. Connect EGR valve to exhaust manifold tube to EGR control valve, LH exhaust manifold and DPFE hose.
4. Install RH and LH engine insulators on cylinder block.
5. Install engine lifting bracketry from Rotunda Engine Lifting Kit 014-00340 or equivalent.
Engine Lifting Brackets, RH Side
Engine Lifting Brackets, LH Side
6. Remove engine from stand using spreader bar and chains from Rotunda Engine Lifting Kit 014-00340 or equivalent.
7. Install transmission to cylinder blocks. Tighten transmission mounting bolts to 40-60 N-m (30-44 lb-ft).
8. Position engine and transmission assembly on subframe assembly.
9. Install insulator through bolts. Tighten to 20-30 N-m (15-22 lb-ft).
10. Raise engine, transmission and subframe assembly into position.
11. Align subframe to body and install subframe-to-body bolts. Tighten to 95-130 N-m (73-100 lb-ft).
12. Connect steering shaft coupler at rag joint.
13. Install rear transmission isolator retaining bolts. Tighten to 20-30 N-m (15-22 lb-ft).
14. Remove Rotunda Powertrain Lift 014-00765 or equivalent and position out of way.
15. Install starter motor. Refer to ((Section 03-06)).
16. Connect low oil level sensor and lower engine wiring harness.
17. Install starter cable and two retaining nuts to lower front cover studs.
18. Install driveshaft to transmission.
19. Lift rear differential into position.
20. Install two nut and bolt assemblies retaining the front of the differential to the rear subframe. Tighten to 98-120 N-m (72-89 lb-ft).
21. Tighten two differential isolator nuts to 102-127 N-m (75-89 lb-ft).
22. Align driveshaft to companion flange and install four retaining bolts. Tighten to 95-130 N-m (70-95 lb-ft).
23. Connect lower transmission cooler line to radiator. Refer to ((Section 07-01)).
24. Connect transmission wiring harness and shift linkage. Refer to ((Section 07-01)).
25. Position lower control arms to strut and install retaining bolt. Tighten to 160-220 N-m (118-162 lb-ft).
26. Install lower radiator hose.
27. Connect power steering pressure line. Refer to ((Section 11-02)).
28. Connect ground strap to RH fender apron.
29. Install exhaust Y-pipe. Refer to ((Section 09-00)).
30. Connect upper control arms to spindles. Tighten to 68-92 N-m (50-68 lb-ft).
31. Connect ride height sensor wiring connectors.
32. Install brake calipers. Refer to ((Section 06-03)).
33. Install front wheel and tires. Refer to ((Section 04-04)).
34. Lower vehicle.
35. Connect A/C lines to compressor. Refer to ((Section 12-03)).
36. Remove engine lifting brackets from Rotunda Engine Lifting Kit 014-00340 or equivalent.
37. Connect upper transmission cooler line. Refer to ((Section 07-01)).
38. Install power steering reservoir. Connect power steering return line to reservoir. Connect power steering supply hose. Refer to ((Section 11-02)).
39. Install coolant supply hose to reservoir.
40. Connect upper radiator hose at crossover pipe.
41. Connect heater supply and return hoses.
42. Connect chassis vacuum supply hose.
43. Connect canister purge vacuum line.
44. Connect accelerator and speed control cables.
45. Connect engine wiring harness to canister purge (CANP) solenoid assembly.
46. Connect generator B+ wiring connector and install power distribution box.
47. Connect 42-pin connector.
48. Install 42-pin connector to retaining bracket.
49. Connect fuel tubes. Refer to ((Section 10-01)).
50. Install cooling fan and shroud. Refer to ((Section 03-03)).
51. Install windshield wiper module. Refer to ((Section 01-16)).
52. Install engine air cleaner outlet tube assembly and resonator assembly.
53. Connect IAT sensor connector and crankcase vent tube.
54. Fill engine with oil as outlined.
55. Fill power steering reservoir. Refer to ((Section 11-02)).
56. Fill engine and radiator with coolant. Refer to ((Section 03-03)).
57. Start engine and check for leaks.
58. Top off all fluids.
59. Recharge air conditioning system. Refer to ((Section 12-00)).
60. Install engine appearance cover.
61. Check front end alignment. Refer to ((Section 04-00)).