Installation
EngineSpecial Tools:
Special Tool(s)
Installation
All engines
1. Remove the engine from the engine stand.
2. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the aluminum retainer plate. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
Clean and inspect the mating surface.
3. NOTE: If not secured within four minutes, sealant must be removed and sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply a bead of sealant around the rear oil seal retainer sealing surface.
4. Install the crankshaft rear oil seal retainer and bolts.
5. Install a new crankshaft rear oil seal.
6. Install the crankshaft oil slinger.
7. Install the flywheel and the bolts. Tighten the bolts in the sequence shown.
8. Support and position the transmission.
9. Install the engine assembly in the vehicle.
10. Raise the vehicle.
11. NOTE: When vehicle is raised verify that the torque converter is correctly seated and the index-marks made during removal are lined up.
Install the five bolts and one stud.
12. Install the ground wire and the nut.
13. Install the RH bolt.
14. Install the LH bolts.
15. Install the four nuts through the torque converter access panel.
16. Install the inspection cover and the bolts.
17. Install the starter motor and install the bolts.
18. Connect the starter electrical connections and install the nuts.
19. Position the exhaust and install the four nuts.
20. NOTE: Some vehicles are not equipped with an oil cooler.
Connect the two coolant hoses, position the clamp and install the oil cooler.
21. Position the transmission oil cooler lines and install the bolt.
22. Lower the vehicle.
23. Install the bolt.
24. Connect the PSP hose.
25. Connect heated oxygen sensor and position the transmission harness retention clip on the stud.
26. Connect the engine bulkhead connectors.
27. Connect the RH heated oxygen sensor electric connector and snap into the transmission oil indicator tube.
28. Position the ground strap and install the bolt.
29. Connect the heater water hoses.
30. Connect the main vacuum supply hose.
Gasoline engines
31. Position the EVAP canister purge valve and install the nut.
32. Connect the three hoses and the EVAP canister purge valve electrical connection.
33. Position the accelerator cable and the speed control actuator cable and install in the clips.
All engines
34. Connect the accelerator cable and the speed control actuator cable:
^ Install the bolts.
^ Connect the cables.
35. Connect the air conditioning lines.
36. Install the nut and the A/C line bracket.
37. Connect the A/C cycling switch electrical connector.
Gasoline engines
38. Position the wire and install the nut; connect the electrical connections at the RH inner fender.
Natural gas engines
39. Connect the connectors.
40. Install the wires.
41. Install the cover.
All engines
42. Position the ground wires and install the bolt.
43. Install the radiator assembly.
44. Install the brackets and the bolts.
45. Connect the lines to the A/C condenser core and install the nuts.
46. Connect the fan motor.
47. Connect the upper radiator hose to the water outlet adapter.
48. Connect the hoses to the power steering fluid cooler.
49. Connect the hoses to the transmission fluid cooler.
50. Install the radiator upper sight shield.
51. Install the battery.
52. Connect the lower radiator hose to the oil filter adapter.
53. Install the air cleaner outlet tube.
54. Install the wiper mounting arm and pivot shaft.
55. Fill the crankcase with clean engine oil.
56. Fill and bleed the cooling system.
57. Fill the power steering system.
58. Evacuate and recharge the air conditioning system.,
59. Install the hood.