Steps 1 - 50

INSTALLATION

Engine

Special Tools And Equipment:

Special Tools

Material:

Material

Installation

All vehicles

CAUTION: If used as a leverage device, the fuel rail can be damaged. Care must be taken when working around the fuel rail.





1. Position the engine in the vehicle and remove the floor crane and the special tools.





2. Install the RH engine support insulator nuts.
^ Tighten to 80 Nm (59 ft. lbs.).





3. Install the radiator and A/C condenser as an assembly.





4. Position the RH radiator support bracket and the bolts.
^ Tighten to 12 Nm (9 ft. lbs.).





5. Position the LH radiator support bracket and the bolts.
^ Tighten to 12 Nm (9 ft. lbs.).





6. Remove the special tool from the RH side of the engine.





7. Remove the special tool from the LH cylinder head.





8. Using the special tool, install a new seal on the power steering pressure (PSP) hose fitting.





9. Connect the PSP hose to the power steering pump.
^ Tighten to 65 Nm (48 ft. lbs.).





10. Install the PSP hose support bracket and the bolt.
^ Tighten to 11 Nm (8 ft. lbs.).





11. Install the LH support insulator through bolt.
^ Tighten to 110 Nm (81 ft. lbs.).





12. Connect the power steering return hose.





13. Remove the special tool.






14. NOTE: Make sure the stud and flexplate marks made during removal line up.

Position the transmission in the vehicle.





15. Install the 8 engine to transmission bolts.
^ Tighten to 48 Nm (35 ft. lbs.).





16. Position the transmission cooler tubes, and the bracket and install the nut.
^ Tighten to 19 Nm (14 ft. lbs.).





17. Connect the transmission cooler tubes.





18. Install the transmission cooler tube clips.






19. CAUTION: Use care not to bend or force the transmission cooler tubes. Damage to the tubes or the transmission can occur. Use a wrench to hold the fittings mounted in the transmission.

Connect the cooler tubes to the transmission.
^ Tighten to 35 Nm (26 ft. lbs.).





20. Connect the harness retainers.






21. CAUTION: Damage will occur to the solenoid body assembly if the screw is tightened above the specification.

NOTE: Always install new O-ring seals on the vehicle harness connector.

NOTE: Clean the area around the connector to prevent contamination of the solenoid body connector.

NOTE: Use petroleum jelly to lubricate the O-ring seals to aid the installation process.

Lubricate and install new O-ring seals on the transmission body electrical connector, connect the electrical connector and tighten the screw.
^ Tighten to 5 Nm (44 inch lbs.).





22. Connect the electrical connectors.





23. Connect the digital Transmission Range (TR) sensor.





24. Move the rubber boot back into position.






25. NOTE: Match the identifying mark on the nut, stud and flexplate to allow for correct installation.

Install the 4 torque converter nuts.
^ Rotate the crankshaft to access all the nuts.
^ Tighten to 38 Nm (28 ft. lbs.).





26. Connect the LH catalyst monitor connector to the transmission.





27. Connect the LH heated oxygen sensor (HO2S) electrical connector retainer and the harness clip to the transmission.





28. If equipped, connect the shift motor electrical connector.





29. Connect the RH HO2S electrical connector to the transmission.





30. Connect the RH catalyst monitor connector and the fuel tubes to the bracket.






31. CAUTION: If new bolts to retain the driveshaft to the axle are not available, coat the threads of the original bolts with thread-lock and sealer.

CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. To make sure that the driveshaft flange seats squarely on the pinion flange, tighten the bolts evenly in the sequence shown.

NOTE: Align the marks made on the flange and driveshaft during removal.

NOTE: On 2 wheel drive vehicles, align the marks on the transmission output shaft.

Position the driveshaft and install the driveshaft to pinion flange bolts in the sequence shown.
^ Tighten to 112 Nm (83 ft. lbs.).

4x4 vehicles






32. CAUTION: If new bolts to retain the driveshaft to the axle are not available, coat the threads of the original bolts with thread-lock and sealer.

CAUTION: The driveshaft flange fits tightly on the transfer case flange. To make sure that the driveshaft flange seats squarely on the transfer case flange, tighten the bolts evenly in a cries cross pattern.

NOTE: Align the marks made on the flange and driveshaft during removal.

Install the rear driveshaft to transfer case flange bolts in the sequence shown.
^ Tighten to 112 Nm (83 ft. lbs.).






33. NOTE: Install new flange bolts and washers.

Position the front driveshaft flange with the location marks aligned and install the retaining bolts finger tight.






34. NOTE: Use new bolts and U-joint straps.

Connect the front driveshaft to the front differential and install new bolts.
^ Tighten to 18 Nm (13 ft. lbs.).





35. Tighten the front driveshaft flange bolts in the sequence shown.
^ Tighten to 30 Nm (22 ft. lbs.).

All vehicles





36. Position the bracket and install the bolts, Connect the shift cable.
^ Tighten to 40 Nm (30 ft. lbs.).

4x4 vehicles





37. Support the transfer case with a suitable jack stand.





38. Disconnect the safety chain and remove the transmission lack.

All vehicles






39. NOTE: The assistance of another technician may be required.

Position the transmission mounted exhaust hanger, the 3 way converter system and RH heat shield.
1 If removed, position the mount and install the bolt.
^ Tighten to 90 Nm (66 ft. lbs.).

2 Position the exhaust hanger and the converter assembly and install the bolt.
^ Tighten to 90 Nm (66 ft. lbs.).






40. NOTE: LH shown, RH similar. Install the 4 converter to manifold nuts.

^ Tighten to 40 Nm (30 ft. lbs.).






41. NOTE: Use a new gasket and new flag nuts.

Connect the muffler to the converter and install the 2 bolts, 2 springs and 2 flag nuts.
^ Tighten to 40 Nm (30 ft. lbs.).






42. NOTE: RH shown, LH similar.

Install the crossmember and the 4 lower bolts.
^ Tighten to 70 Nm (52 ft. lbs.).






43. NOTE: RH shown, LH similar.

Install the 4 upper crossmember bolts.
^ Tighten to 70 Nm (52 ft. lbs.).

4x2 vehicles





44. Remove the transmission jack from the transmission.





45. Install the cable bracket and the bolts to the transmission.
^ Tighten to 40 Nm (30 ft. lbs.).

4x4 vehicles





46. Remove the jack stand from under the transfer case.

All vehicles





47. Install the plastic shield and the 2 nuts on the right side of the crossmember.
^ Tighten to 9 Nm (80 inch lbs.).





48. Install the crossmember to transmission support insulator nuts.
^ Tighten to 90 Nm (66 ft. lbs.).





49. Install the LH heat shield bolt.
^ Tighten to 20 Nm (15 ft. lbs.).





50. Install the RH heat shield bolts.