Engine - Installation

INSTALLATION

Special Tools:











NOTE: Do not use air tools to install Engine Lift Fixture (1).

1. Install the Engine Lift Fixture (1).
2. Connect a suitable engine lifting devise to the Engine Lift Fixture (1).
3. Position the engine in the vehicle.





4. Lower and align the engine (1) with the transmission (3).
5. Continue to lower the engine assembly until the engine mounting brackets lineup with the engine mounts.
6. Install two transmission to engine block mounting bolts (2) finger tight.
7. Remove the engine lifting devise.
8. Raise and support the vehicle.




4x4 rear engine mount isolator shown, 4x2 rear engine mount isolator similar.
9. Using a suitable transmission hydraulic jack, slightly raise the transmission and remove the block of wood between the transmission and engine cradle crossmember, lower the transmission and remove the jack.
10. Tighten the rear engine mount isolator retaining bolts (1) to 61 Nm (45 ft. lbs.).





11. Install the remaining transmission bell housing-to-engine block retaining bolts (2) and tighten to 68 Nm (50 ft. lbs.).





12. Install all torque converter-to-flexplate bolts (1) finger tight.
13. Verify the torque converter is pulled flush to the flexplate and tighten bolts to 31 Nm (23 ft. lbs.).




Left side shown, right side similar.
14. Install the engine mount retaining nuts (2) and tighten to 95 Nm (70 ft. lbs.).






CAUTION: The structural dust cover must be installed as described in the following steps. Failure to do so may cause severe damage to the cover.

15. Position the structural cover (2) in the vehicle.
16. Install the structural dust cover bolts (1) to the engine block finger tight.
17. Install the structural dust cover bolts (1) to the transmission finger tight.

CAUTION: The structural dust cover must be held tightly against both the engine and the transmission bell housing during the tightening sequence. Failure to do so may cause severe damage to the cover.

18. Tighten the structural dust cover bolts to the transmission to 9 Nm (80 in. lbs.).
19. Tighten the structural dust cover bolts to the engine block to 9 Nm (80 in. lbs.).
20. Again, tighten the structural dust cover bolts to the transmission to 54 Nm (40 ft. lbs.).
21. Again, tighten the structural dust cover bolts to the engine block to 54 Nm (40 ft. lbs.).





22. Lower the vehicle.
23. Remove the Engine Lift Fixture (1).
24. Position the engine harness on both right and left sides of the vehicle.






NOTE: Ensure that the O-ring is fully seated into the cylinder block.

25. Position the oil control valve (3) into the cylinder block.
26. Securely tighten the oil control valve retaining bolt (2).
27. Connect the oil control valve electrical connector (1).
28. Install the intake manifold Intake Manifold - Removal.





29. Install the generator Generator - Installation.
30. Install the cooling fan module (1) Cooling Fan - Removal.





31. Position both heater hoses (2).
32. Install both heater hose clamps (1).





33. Position the upper radiator hose and secure the retainer (2) at the fan shroud.
34. Connect the upper radiator hose to the thermostat housing and install the hose clamp (1).
35. Raise and support the vehicle.





36. Install the starter (1) Starter - Removal.
37. Install the A/C compressor to the engine block A/C Compressor - Installation.
38. Connect the transmission oil cooler lines to their retainer at the oil pan.





39. Install both exhaust pipe/catalytic converters Catalytic Converter - Installation.
40. Position the left catalytic converter heat shield (2) install the retaining bolts (1) and securely tighten.





41. Connect the lower radiator hose (3) to the radiator and install the hose clamp (2).
42. Connect the lower radiator hose to the water pump and install hose clamp (1).





43. If equipped, position the skid plate, install the four retaining bolts (2) and tighten to 28 Nm (21 ft. lbs.).
44. Lower the vehicle.





45. Connect the left upstream 02 sensor electrical connector (1).





46. Connect the right upstream 02 sensor electrical connector (1).
47. Connect all remaining left and right engine harness electrical connectors.





48. Install the power steering pump (1) Power Steering Pump - Installation.
49. Install the serpentine belt Serpentine Accessory Drive Belt - Installation.





50. Install the cowl panel cover (2) Cowl Panel Cover - Installation.
51. Start the engine and inspect for leaks.
52. Install the air cleaner and resonator assembly Air Cleaner Body - Installation.





53. Fill the engine with oil .
54. Fill the cooling system Service and Repair.
55. Connect the negative battery cable (2).





56. Install the engine cover (2).
57. Install the oil fill cap (1).
58. Start the engine and check for leaks.
59. Road test vehicle.