Installation
ENGINE REMOVAL / INSTALLATION - 4.0LInstallation
All vehicles
Caution: If the fuel supply manifold is used as a leverage device, damage can occur to the supply manifold. Care must be taken when working around the fuel supply manifold.
1. Install the engine, remove the floor crane and the spreader bar.
2. Install the LH engine insulator nuts.
3. Install the RH engine insulator nuts.
Note: Automatic transmission shown, manual transmission similar.
4. Install the eight transmission-to-engine bolts.
5. If equipped with A/C, position the A/C tube bracket and install the nut.
6. Route the transmission/transfer case portion of the wiring harness down to the transmission.
7. Attach the transmission/transfer case portion of the wiring harness to any routing clips or pin-type retainers.
8. Connect the wiring harness electrical connector located on the frame.
9. Position the Y-Pipe and install the gasket, the bolts and the nuts.
10. Install the nuts.
11. Install the nuts.
12. Connect the LH heated oxygen sensor (HO2S) electrical connector.
13. Connect the RH (HO2S) electrical connector.
14. Connect the RH (HO2S) electrical connector
15. Install a new engine oil filter.
Vehicles equipped with a manual transmission
16. Connect the following:
1 Connect the output shaft speed (OSS) sensor electrical connector.
2 Attach the heated oxygen sensor (HO2S) electrical connector to the bracket.
17. Connect the reversing lamp switch electrical connector.
Vehicles equipped with an automatic transmission
18. Install the four torque converter nuts.
19. Position the transmission cooling tube bracket and install the bolt.
20. Connect the output shaft speed (OSS) sensor and digital transmission range (TR) sensor electrical connectors.
21. Connect the transmission control and input shaft electrical connectors. Install the wiring harness pin-type retainer.
22. Position the transmission level indicator tube and install the nut.
All vehicles
23. Install the starter.
24. Connect the heater hose.
25. Connect the heater hose.
26. Install the crankcase breather hose and connect the two vacuum hoses (one shown).
Early build vehicles
27. Install the vapor hose and attach the pin-type retainer.
28. Connect the vapor hose.
Late build vehicles
29. Connect the vapor hose to the purge valve.
30. Connect the vapor hose to the intake manifold.
All vehicles
31. Connect the brake booster vacuum hose.
32. Position the engine ground wire and install the retainer.
33. Position the powertrain control module (PCM) electrical ground wire and install the retainer.
34. Connect the PCM electrical connector and tighten the bolt.
35. Position the engine wiring harness and install the retainer nut.
36. Connect the engine wiring harness electrical connector and tighten the bolt.
Note: 2WD shown, 4WD similar.
37. Install the engine wiring harness bracket and bolt and connect the oil pressure sensor electrical connector.
38. Position the wiring harness and install the bolt.
39. Connect the generator wiring.
40. Position the accessory bracket, the A/C compressor if equipped, and the power steering pump and power steering fluid reservoir as an assembly and install the accessory bracket bolts.
Note: The battery is removed for clarity.
41. Connect the power steering return hose to the power steering fluid reservoir.
42. Connect the power steering high pressure hose to the lower power steering pump flitting.
43. If equipped with A/C, position the A/C compressor manifold tube and install the bolt.
44. If equipped with A/C connect the A/C high pressure switch electrical connector.
45. If equipped with A/C, connect the A/C field coil electrical connector.
46. Install the accessory drive belt.
47. Connect the accelerator and cruise control cables.
1 Position the cables and connect the accelerator and cruise control cables to the bracket.
2 Connect the accelerator and cruise control cables to the throttle body.
Note: Do not fill the cooling system at this time.
48. Install the radiator.
49. Install the air cleaner housing cover.
50. Connect the mass air flow (MAF) sensor.
51. Install the fan blade.
52. Install the hood.
53. Connect the spring lock couplings.
54. Connect the negative battery cable.
55. Fill the engine to the correct oil level with clean engine oil.
56. Fill the engine cooling system.
57. Fill the power steering system.
58. If equipped with A/C, recharge the A/C system.