Installation

Special Tool(s)




Material

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





2. NOTE: The engine must be to the left of the center line to install.

Raise the engine high enough to clear the No.1 crossmember and position the engine into the vehicle.





3. NOTE: Left side shown, right side similar.

Position the motor mounts in the vehicle.





4. Align the torque converter studs with the holes in the flywheel and push the engine in. Install the top engine-to-transmission bolts.





5. NOTE: Front bolts shown, rear bolts similar.

Lower the engine until it is just above the motor mounts. Install the retaining bolts in the RH motor mount.





6. Install the four retaining bolts in the LH motor mount.
7. Remove the transmission jack.





8. Install a new O-ring seal on the oil pickup tube and position the oil pickup Cube in the oil pan.





9. Install a new press-in-place gasket into the upper oil pan.
10. Position the oil pan in the vehicle.





11. Install the oil pickup tube and bolts.





12. Position the oil pan and install the bolts.
1 Install the longer oil pan bolts.
2 Install the remaining oil pan bolts.
^ Tighten the bolts to 13 Nm (10 ft. lbs.).





13. Clean and inspect the oil pan drain plug and gasket. Install new, if necessary.





14. Install the oil pan drain plug.





15. Lower the engine. Remove the lifting crane and the engine lifting attachment.





16. Remove the special tool.





17. Install the factory engine lifting bracket.
18. Loosely install the turbocharger exhaust pipe.





19. Remove the special tools.





20. NOTE: Remove the plug or cap as needed.

Install the injection control pressure (ICP) sensor.





21. NOTE: Remove the protective covering from the cylinder head.

Install the LH valve cover gasket, valve cover and bolts.





22. Install the glow plug module mounting bracket and retaining nuts.





23. Install the glow plug module and retaining nuts.





24. Connect the exhaust back pressure Tube at the exhaust manifold.





25. NOTE: Install a new O-ring seal and coat with clean engine oil.

Install the oil indicator and Lube. Install the retaining nut. Connect the glow plug wire retainer.





26. Position the fuel tubes and install the mounting bolts for the fuel tube bracket.





27. Install the lower engine-to-transmission bolts.





28. NOTE: Left side shown, right side similar.

NOTE: The top retaining nut must be tightened first.

Install the motor mount nuts.





29. Install the starter motor and bolts.





30. Connect the starter motor electrical connections.





31. Install the starter motor solenoid protective cap.





32. Position the cable bracket and install the retaining nut.





33. Connect the block heater electrical connector.





34. Install the new torque converter nuts.





35. Install the torque converter cover.





36. Install the transmission Pubes and retaining clips.





37. Position the transmission cooler tubes on the stud and install the retaining nut.





38. Install the oil filter assembly and bolts.





39. Position the engine wiring harness and connect the Powertrain Control Module (PCM) electrical connectors.





40. Connect the two electrical connectors.





41. Connect the LH glow plug electrical connector.





42. Connect the push pin retainer and exhaust back pressure sensor electrical connector.





43. CAUTION: Do not use power tools when installing the nut.

CAUTION: Use care not to overtighten the nut during installation.

Connect the B+ wire and reposition the boot.





44. Connect the electrical connector and wire retainers at the transmission.





45. Connect the glow plug module electrical connectors.





46. Connect the camshaft position sensor electrical connector and retaining clips.





47. Position the wiring and connect the glow plug electrical connector. Connect the ICP sensor electrical connector.





48. Connect the Crankshaft Position (CKP) sensor electrical connector and retaining clips.





49. Connect the fuel lines and install the retaining clips.





50. Install the lower radiator hose.





51. Position the power steering pump and install the bolts.





52. Install the LH fan stator stand-off.





53. Install the power steering upper mounting bolts.





54. NOTE: The bolt behind the pulley is accessed through the pulley with an extension and a short socket.

Install the vacuum pump and bolts.





55. Connect the vacuum pump hose and install the engine coolant fill hose clip.





56. Install the engine coolant fill hose and tighten the clamp. Connect the engine fill hose into the retaining clip





57. Install the idler pulley and bolt.





58. Position the heater hose back and connect.





59. Install the A/C compressor and bolts.





60. NOTE: Remove the caps or plugs as needed. Install new O-ring seals and lubricate with PAG oil.

Install the A/C manifold at the tee block. Connect the high-pressure switch electrical connector.





61. Connect the A/C clutch electrical connector.





62. Position back the cable and install the bolt. Install the RH fan stator stand-off.
63. Install the intake manifold.





64. NOTE: LH shown, RH similar.

Install the lower radiator supports and bolts.





65. NOTE: RH shown, LH similar.

Install the upper radiator supports and bolts.





66. Position the hood latch and install the bolts.





67. Position the headlamp wiring harness and connect the air bag sensor. Install the bolts for the air bag sensor.
68. Install the valance panel, radiator grille support and grille opening panel reinforcement.
69. Install the front bumper.
70. Install the A/C condenser assembly.
71. Fill the engine with clean engine oil.
72. Connect the battery ground cable.
73. Check and top off the transmission fluid level.