Steps 1-39

Installation Procedure





1. Install the J 36857 (1) to the rear of the left cylinder head with a suitable bolt.





2. Install the J 36857 (1) to the front of the right cylinder head with a suitable bolt.
3. Install a suitable lifting device. The engine will have to be angled in order to install. Use a load positioning sling to assist in angling the engine.
4. Install the engine assembly in the vehicle.

Important: Do not draw the engine to the transmission using the transmission bolts. If everything is aligned properly the engine and transmission will come together.

5. Loosely install 2 transmission to engine bolts.





Notice: Refer to Fastener Notice in Service Precautions.

6. Install the left and right side engine mount frame brackets.
- Tighten the engine mount frame bracket through-bolts to 75 Nm (55 ft. lbs.).





7. Install the engine mount to frame bracket bolts (left side shown).
- Tighten the engine mount to frame bolts to 65 Nm (50 ft. lbs.).
8. Remove the J 36857 from the cylinder heads.
9. Raise the vehicle.





10. Install the transmission to engine' bolts (automatic transmission shown).
- Tighten the transmission to engine studs and bolts to 50 Nm (37 ft. lbs.).




11. If equipped with an automatic transmission install the torque convertor bolts.
- Tighten the torque converter bolts to 60 Nm (44 ft. lbs.).





12. If equipped with an automatic transmission, install the nuts retaining the transmission fluid fill tube bracket.
- Tighten the transmission fluid fill tube bracket nuts to 18 Nm (13 ft. lbs.).
13. If the vehicle is 4WD, install the lower oil pan.





14. If equipped with an automatic transmission, install the nut retaining the transmission oil cooler line clip.
- Tighten the transmission oil cooler line clip bolt to 9 Nm (80 inch lbs.).





15. Install the exhaust pipe to the exhaust outlet.
16. Install the exhaust manifold pipe to the exhaust outlet clamp.
- Tighten the exhaust pipe clamp to 40 Nm (30 ft. lbs.).
17. Lower the vehicle to work through the front fender wheelhouse openings.





18. Install the bolt retaining the battery negative cable and the engine wiring harness ground wire to the left side of the engine.
- Tighten the ground wire bolt to 34 Nm (25 ft. lbs.).





19. Install the bolts holding the battery cable channel retainer to the lower crankcase.
- Tighten the cable bracket bolts to 12 Nm (106 ft. lbs.).





20. Install the bolts holding the auxiliary battery negative cable and the engine wiring harness ground wires to the right side of the engine.
- Tighten the cable and ground wire bolts to 34 Nm (25 ft. lbs.).





21. Install the nut holding the battery cable bracket to the right side of the lower crankcase.
- Tighten the cable bracket nut to 8 Nm (71 inch lbs.).
22. Install the starter.





23. Connect the cord for the engine coolant heater.





24. Install the engine oil pan skid plate.
- Tighten the oil pan skid plate bolts to 20 Nm (15 ft. lbs.).





25. Install the engine protection shield.
- Tighten the engine protection shield bolts to 20 Nm (15 ft. lbs.).
26. Lower the vehicle.





27. Install the bolt and the ground wires at the rear of the left cylinder head.
- Tighten the ground wire bolt to 25 Nm (18 ft. lbs.).





28. Install the generator mounting bracket and bolts.
- Tighten the generator mounting bracket bolts to 50 Nm (37 ft. lbs.).





29. Install the right idler pulley.
- Tighten the idler pulley bolt to 43 Nm (32 ft. lbs.)..





30. Install the PCV oil separator bracket and the fuel bleed with the nuts to the generator mounting bracket.
- Tighten the bracket nuts to 25 Nm (18 ft. lbs.).
31. Install the PCV oil separator on the bracket.
32. Install a nylon strap for the PCV oil separator.
33. Install the air conditioning compressor and the power steering pump mounting bracket.





34. Position the engine wiring harness on the engine.
35. Position the A/C compressor.
36. Install the A/C compressor mounting bolts.
- Tighten the A/C compressor mounting bolts to 50 Nm (37 ft. lbs.).
37. Install the A/C suction hose to the accumulator.
38. Install the drive belt.





39. Install the power supply cable and nut to the glow plug relay.
- Tighten the glow plug supply cable nut to 2 Nm (18 inch lbs.).