Removal & Installation: Engine: Installation

1. Position the engine/transmission into the engine compartment and lower the assembly into position. See Fig 37.
2. Align the engine mount brackets to the front engine mounts and install the engine mount nuts. See Fig 31. Tighten the engine mount nuts to specification. See TORQUE SPECIFICATIONS .
3. Operate the engine hoist and the vehicle lift simultaneously to raise the vehicle to a convenient working height.
4. Position a transmission jack and raise the support bed of the jack to take the weight of the transmission. Install and adjust the chains to secure the transmission to the jack. See Fig 35.
5. Install the crossmember mounting assembly. Install, but do not tighten the 4 crossmember mounting assembly bolts. See Fig 36. Install the transmission mount nut. See Fig 34. Tighten the transmission mount nut and the crossmember bolts to specification. See TORQUE SPECIFICATIONS .
6. Release transmission jack chains and remove the transmission jack.
7. Operate the engine hoist and the vehicle lift simultaneously to lower the vehicle to a convenient working height.
8. Lower the engine hoist and remove the chain assembly and engine lifting brackets. See Fig 30. Move the engine hoist away from the vehicle.
9. Raise and support the vehicle. Install the selector lever of the transmission selector cable to the transmission cross shaft. Install the transmission cross shaft nut. Install the selector cable bracket to the transmission and install the selector cable bracket bolts. See Fig 33. Tighten cross shaft nut and selector cable bracket bolts to specification. See TORQUE SPECIFICATIONS .
10. Connect the transmission harness connector and secure the connector lock lever. See Fig 32.
11. Install and tighten the ground cable to the transmission housing. See Fig 20.
12. Install the downpipe catalytic converter bracket to the bell housing. See Fig 15. Install the 2 mounting bracket bolts and tighten to specification. See TORQUE SPECIFICATIONS . Repeat for the other catalytic converter.
CAUTION: To preserve drive line integrity, individual parts other than the flange bolts, MUST NOT be renewed. In the event of any balance or drive shaft component related problem, the complete assembly must be replaced. Under no circumstances may the flexible coupling be removed or loosened from the drive shaft. Do not drop or subject the drive shaft to damage.
NOTE: To tighten the final drive coupling assembly bolts to specification, Torque Adaptor (Snap-on FRDHM13) or equivalent must be used with one of the following methods: Using a torque wrench calibration machine, apply the specified torque at the calibrator (using the torque adaptor) and note the corresponding reading at the torque wrench. Or, using a formula to calculate the effect of the added length. Length RS = (W x T) / (W + L). Where RS = Torque wrench setting; W = Effective length of the torque wrench; T = Torque specification; L = Length of adaptor. Example: Using a torque wrench 13.0 In. (330 mm or 0.33 m) long and an adaptor 2.0 In. (50 mm or 0.05 m) long, calculate as follows for a specified torque of 44 Ft. Lbs. (60 N.m). Standard: RS = (13 x 44) / (13 + 2) or 572 / 15 = 38. Metric: RS = (0.33 x 60) / (0.33 + 0.05) or 19.8 / 0.38 = 52.1 N.m.
13. Noting the position marked during removal and using NEW bolts, install the drive shaft to the final drive flange. Tighten the 4 coupling assembly bolts to specification. See TORQUE SPECIFICATIONS . See Fig 38.
14. Noting the position marked during removal and using NEW bolts, move the drive shaft sliding joint from the minimum length position and install the drive shaft to the transmission flange. Tighten the 3 coupling assembly bolts to specification. See TORQUE SPECIFICATIONS . See Fig 17.
15. Install a NEW gasket to the downpipe catalytic converter flange and install the downpipe catalytic converter to the exhaust manifold. Install the downpipe catalytic converter-to-lower mounting bracket bolts but do not tighten. Repeat for the other downpipe catalytic converter. Lower vehicle.
16. Install and tighten the downpipe catalytic converter-to-exhaust manifold flange nuts (both "A" bank and "B" banks). See TORQUE SPECIFICATIONS . See Fig 13.
17. Raise and support the vehicle. Slide front muffler up and connect to the downpipe catalytic converters. Slide muffler back and connect to the intermediate muffler. Align as necessary, reposition all muffler clamps and tighten clamps to specification. Tighten the downpipe catalytic converter-to-lower mounting bracket bolts to specification. See TORQUE SPECIFICATIONS .
18. If equipped, connect the oil cooler lines to the engine. Remove the plugs from the oil cooler lines and fittings on the engine. Install NEW "O" rings on the oil cooler lines and lubricate with clean engine oil. Install the oil cooler lines to the engine. Install the clamping plate with bolt and tighten to specification. See TORQUE SPECIFICATIONS . See Fig 21.
19. Install the parking brake relay lever mounting bracket. See Fig 16. Lower the vehicle.
20. Install the heater return and supply hoses. Tighten heater hose clamps. Install the brake servo hose. See Fig 29.
21. Install the engine management harness connector to the mounting bracket. Connect the engine management harness connectors and tighten the bolt. See Fig 24.
22. Noting position marked during removal, connect the transmission rotary switch harness connector and oxygen sensor connectors. Install connector to mounting bracket. See Fig 12.
23. Install the throttle cable bracket and throttle cable bracket screws. Rotate the throttle actuator cam and connect the throttle cable and position the cable into the cam. Remove any tape or plastic tie strap. Tighten throttle cable bracket screws to specification. See TORQUE SPECIFICATIONS . See Fig 28.
24. Connect the partial load breather hose and tighten the clamp securing the part load breather hose to the purge valve. Connect the vacuum hose to the purge valve. See Fig 27.
25. Connect the fuel feed hose to the fuel feed pipe. See Fig 25. Ensure that quick fit connector is fully seated to the fuel feed pipe.
26. Connect the fuel return hose to the fuel return pipe. See Fig 26. Ensure that the quick fit connector is fully seated to the fuel return pipe.
27. Route the positive cable through the heatshield and install the cable to the starter motor positive cable stud. Install and tighten the nut to the stud. Reposition the protective boot over the starter cable power stud. Connect the engine management harness-to-starter motor connector. Install the connector to the mounting bracket and secure the cable with a NEW tie strap. See Fig 23.
28. If equipped, connect the generator suppression module harness connector and reposition the harness under the suppression module. See Fig 22.
29. Remove the plugs and cap from the power steering lines and fittings. Install a NEW sealing washer to the high pressure hose, install and tighten the high pressure line. Install the supply hose to the pump and position the hose clamp to secure the hose. See Fig 11.
30. Connect the engine oil pressure sensor connector. See Fig 10.
31. Install the radiator. See RADIATOR .
32. Connect the lower expansion tank hose to the expansion tank and install and position the hose clamp to secure the hose. Install the expansion tank to the left side enclosure panel. See Fig 9.
33. Connect the coolant level sensor connector. Install the tank to the rear mounting grommets and install expansion tank bolt. See Fig 8.
34. Install the expansion tank-to-thermostat housing hose and the radiator air bleed hose to the expansion tank. Position the hose clamps to secure the hoses. See Fig 7.
35. Install a NEW air intake tube-to-throttle body seal. Install a NEW "O" ring to the "A" bank breather pipe and install the air intake tube/airflow meter/air cleaner cover assembly. See Fig 6.
36. Secure the 5 air cleaner cover clips and connect the airflow meter connector. See Fig 5.
37. Connect the air intake tube to the throttle body and install the 2 bolts which secure the air intake tube to the throttle body. See Fig 4.
38. Install a NEW strap to secure the vacuum pipe to the intake manifold elbow.
39. Connect battery. See BATTERY RECONNECT PROCEDURE  under MISCELLANEOUS.
40. Refill the cooling system. See COOLING SYSTEM .
NOTE: When the engine is started from cold and run for only a short period before being switched off, a quantity of oil will be "hung up" within the engine because it is not up to operating temperature. Should the oil level be topped-up at this time, the level could become too high, causing oil burning. Typically 0.9 Qt. (0.875 L) is "hung up" within the engine.
41. Refill the engine with engine oil of the correct specification.
42. Refill the automatic transmission.
43. Refill and bleed the power steering system.
44. Using approved A/C equipment, evacuate and recharge A/C system.
45. Check for leaks and that all lines and hoses are securely connected. Carefully install the engine covers, taking care not to damage the plastic retainers or the rubber inserts.
46. With assistance, install the engine compartment hood and install the 6 bolts. Install the ground lead to the original location on the left hand hinge. See Fig 2.
47. Move the engine compartment hood from the service position and connect the gas struts. See Fig 1. Remove the body protection covers and close the engine compartment hood.