Steps 1 - 50

INSTALLATION

Engine

Special Tools And Equipment:

Special Tools

Material:

Material

Installation

All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.





2. Position the engine in the vehicle and remove the special tool and the engine crane.





3. Remove the wire tie or mechanic's wire from the fuel hose.





4. Remove the special tool from the right side of the engine.





5. Position the ground strap and install the stud bolt.
^ Tighten to 12 Nm (9 ft. lbs.).





6. Connect the fuel charging wiring harness electrical connectors.





7. Attach the harness retaining clip to the ground stud bolt.





8. Connect the fuel charging wiring harness push pins.





9. Install the LH engine support insulator through bolt.
^ Tighten to 103 Nm (76 ft. lbs.).





10. Install the washer and nut on the RH engine support insulator.
^ Tighten to 90 Nm (66 ft. lbs.).





11. Using the special tool, install a new seal on the power steering pressure hose fitting.





12. Connect the power steering pressure hose.
^ Tighten to 66 Nm (48 ft. lbs.).





13. Connect the power steering return hose and position the clamp.





14. Position the cooler tubes and install the nut.
^ Tighten to 10 Nm (89 inch lbs.).





15. Attach the LH Heated Oxygen Sensor (HO2S) wiring harness.






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

Position the transmission and, if equipped, the transfer case.





17. Install the 7 engine to transmission bolts.
^ Tighten to 48 Nm (35 ft. lbs.).





18. Remove the wooden support.





19. Install the 4 torque converter nuts.
^ Turn the crankshaft using the crankshaft pulley bolt.
^ Tighten to 38 Nm (28 ft. lbs.).





20. Install the access cover.





21. Position the cover and install the bolts.
^ Tighten to 34 Nm (25 ft. lbs.).





22. Position the starter and install the bolts.
^ Tighten to 26 Nm (18 ft. lbs.).





23. Install the starter wires.
1 Position the solenoid wire and install the nut.
^ Tighten to 6 Nm (53 inch lbs.)

2 Position the battery cable and install the nut.
^ Tighten to 12 Nm (9 ft. lbs.)





24. Install the cap.






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

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





26. Position the front crossmember and install the bolts.
^ Tighten to 70 Nm (52 ft. lbs.).

AWD vehicles





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





28. Disconnect the safety chain and remove the transmission jack.





29. If equipped, connect the shift motor electrical connector and wiring harness pin type retainer(s).

All vehicles





30. Attach the RH catalyst monitor sensor electrical connector and the fuel tubes to the bracket.





31. Attach the LH catalyst monitor sensor electrical connector to the transmission.






32. NOTE: LH shown, RH similar.

Attach the RH HO2S wiring harness retainer to the transmission.





33. Connect the wiring harness retainers.





34. Connect the Transmission Range (TR) sensor electrical connector.
^ Position the rubber boot over the connector.






35. 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.

Install and lubricate 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.).





36. Connect the Turbine Shaft Speed (TSS) sensor, the Output Shaft Speed (OSS) sensor and the Intermediate Shaft Speed (ISS) sensor electrical connectors.






37. 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, remove the plug placed in the transmission.

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

AWD vehicles






38. 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.
^ Tighten the bolts in the sequence shown to 112 Nm (83 ft. lbs.).






39. CAUTION: The can (domed CV joint housing cover) is pressed into the CV joint housing at the factory. When housed correctly, the can will appear as shown in the cut away illustration, top box. Do not reseat the can in the CV joint housing if the cans flange is above the CV joint housing shown in the cut away illustration, bottom box. Install a new driveshaft.

Verify the can flange is housed correctly in the CV joint housing as shown in the cut away illustration, top box. Install a new driveshaft if the can flange is not housed correctly.






40. CAUTION: Always connect the front driveshaft to the axle first. The weight of the driveshaft can pinch the boot, causing the boot to tear.

CAUTION: Tighten the bolts evenly in a cries cross pattern or damage to the CV joint can occur.

CAUTION: Install new bolts and washers. If new bolts and washers are not available, coat the original bolts with thread-lock and sealer.

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

Install new bolts and washers.
^ Tighten the bolts in the sequence shown to 30 Nm (22 ft. lbs.).






41. CAUTION: Install new universal joint retainers and bolts. If new retainers and bolts are not available, coat the original bolts with thread-lock and sealer.

Install new universal joint retainers and bolts.
^ Tighten to 18 Nm (13 ft. lbs.).

All vehicles





42. Place the manual shift lever in the park position.





43. Position the shift cable and bracket, install the bolts and connect the cable to the manual shift lever.
^ Tighten to 40 Nm (30 ft. lbs.).





44. Position the dual converter Y pipe with the heat shields on a jack stand and loosely install the 4 nuts.





45. Position the transmission rear mount and loosely install the bolts.





46. Position a new gasket, connect the dual converter Y pipe to the muffler and install the bolts, springs and flag nuts.
^ Tighten to 40 Nm (30 ft. lbs.).





47. Tighten the 4 dual converter Y pipe to exhaust manifold nuts.
^ Tighten to 40 Nm (30 ft. lbs.).





48. Tighten the transmission rear mount bolts.
^ Tighten to 90 Nm (66 ft. lbs.).





49. Remove the jack stand from the dual converter Y pipe.






50. NOTE: LH shown, RH similar.

Connect the 2 HO2S electrical connectors.