Engine - Installation

INSTALLATION





1. Install the Engine Lift Fixture (2) 8984A and Bracket 8984-UPD (4).





2. Apply a light coating of Mopar(R) High Temp Grease to the torque converter hub pocket in the rear pocket of the engine's crankshaft.

NOTE: Be sure the transmission dowel pins are seated into the engine block and protrude far enough to hold the transmission in alignment.

3. Lower the engine (1) into the engine compartment and align the engine with transmission (3).

NOTE: Verify that no wires, or transmission vent hoses, have become trapped between the engine block and the transmission.

4. Mate the engine and the transmission and install two transmission to engine block mounting bolts (2) finger tight.





5. Lower engine assembly until engine mount studs (3) rest in frame perches.





6. Raise the vehicle and install the transmission (3) to engine oil pan (2) bolts (1) and tighten bolts to 39 Nm (29 ft.lbs.).





7. Install the remaining torque converter housing to engine bolts and tighten bolts to 68 Nm (50 ft.lbs.).






CAUTION: It is essential that the correct length bolts are used to attach the converter to the driveplate. Bolts that are too long will damage the clutch surface inside the converter.

8. Install all torque converter-to-driveplate bolts (1) by hand, verify the torque converter is pulled flush to the driveplate and tighten bolts to 88 Nm (65 ft. lbs.).





9. Install the torque converter access cover (1) and tighten bolt (2) to 11 Nm (8 ft.lbs.).





10. Install the engine mount to frame nuts (1,2) and tighten nuts to 95 Nm (70 ft. lbs.).






NOTE: The starter is located on the right side of the transmission for RWD vehicles and is located on the left side for AWD vehicles.

11. Install the starter (1) and connect the starter wires Starter - Installation





12. FOR AWD ONLY Install the intermediate shaft (2) to the oil pan (3) and tighten bolts to 28 Nm (21 ft. lbs).
13. FOR AWD ONLY Install the front differential through the opening at the rear of the cradle, and fasten the differential (4) to the oil pan (3) and tighten bolts to 65 Nm (48 ft. lbs).





14. FOR AWD ONLY Install the differential support bracket (1) to the differential and the engine block and tighten bolts to 28 Nm (21 ft. lbs.).





15. FOR AWD ONLY Install the left (2) and right front drive axles. Half Shaft - Installation





16. FOR AWD ONLY Install the propeller shaft (1) into position.
17. FOR AWD ONLY Starting at the transfer case end, align the index marks placed upon removal and by hand and install new propeller shaft-to-transfer case flange bolts.
18. FOR AWD ONLY Align the index marks at the front axle end of the shaft, and by hand install new propeller shaft-to-front axle flange bolts.
19. FOR AWD ONLY Torque the propeller shaft-to-transfer case and axle flange bolts (2) to 61 Nm (45 ft. lbs.).





20. FOR AWD ONLY Install the propeller shaft heat shield and tighten securely.





21. Install the front exhaust pipe/catalytic converter assembly (4) onto the exhaust manifold ball flange (left side shown right side similar) and tighten ball flange nuts (3) to 34 Nm (25 ft. lbs.).
22. Connect the oxygen sensor connectors (2).






NOTE: During the belly pan installation, ensure the rear belly pan is shingled underneath the front belly pan. Failure to do so may result in damage to the belly pan.

23. Install the rear belly pan (2) and tighten screws (1) securely.





24. Install the front belly pan (2) and tighten screws (1) securely.

25. Lower the vehicle.




26. Remove the engine lift fixture (2), special tool 8984A and 8984-UPD (2,4).
27. Connect the fuel supply line Service and Repair





28. Install the three P/S pump mounting bolts (2) through access holes in the pulley and tighten bolts to 28 Nm (21 ft. lbs.) torque.





29. Connect the heater hoses (1).
30. Reconnect the ground wires to the rear of each cylinder head.
31. Install the intake manifold. Intake Manifold - Installation





32. Position the generator (2) to engine and install 2 mounting bolts (1) finger tight.





33. Position the support bracket (1) to the generator and install bolt (3) and nut (4) finger tight.
34. Tighten the generator mounting bolts to 65 Nm (48 ft. lbs.) and the bracket nut (4) to 28 Nm (20.5 ft. lbs.).
35. Snap the field wire connector into the rear of generator.
36. Install the B+ terminal eyelet to the generator output stud and tighten nut to 13 Nm (115 in. lbs.).





37. Install the two upper and lower bolts (3) that secure the front of the A/C compressor (4) to the cylinder block (5) finger tight.
38. Install the rear bolt (2) that secures the automatic transmission cooler line bracket (1) and the rear of the A/C compressor to the cylinder block finger tight.
39. Tighten the three bolts in the following order to 50 Nm (37 ft. lbs.).
- Upper front bolt
- Lower front bolt
- Rear bolt





40. Check the condition of all pulleys.

CAUTION: When installing the serpentine accessory drive belt, the belt MUST be routed correctly. If not, the engine may overheat due to the water pump rotating in the wrong direction.

41. Position the accessory drive belt around all the pulleys except the idler pulley (1). Rotate the tensioner arm (6) until it contacts it's stop position. Route the accessory drive belt around the idler (1) and slowly let the tensioner rotate into the belt. Make sure the belt is seated onto all the pulleys.

NOTE: On all engines, the tensioner (6) is equipped with an indexing tang on the back of the tensioner and an indexing stop on the tensioner housing. If a new belt is being installed, the tang must be within approximately 6 - 8mm (0.24 - 0.32 in.) of the indexing stop (i.e. tang is approximately between the two indexing stops). Belt is considered new if it has been used 15 minutes or less.

42. With the accessory drive belt installed, inspect the belt wear indicator.





43. Position the radiator cooling fan and shroud assembly (1) in the vehicle.
44. Install the cooling fan mounting bolts and tighten to 6 Nm (50 in. lbs.)
45. Connect the cooling fan electrical connector (2).
46. Install the upper radiator hose (3).
47. Connect the lower radiator hose.
48. Connect the transmission oil cooler lines to the radiator.





49. Install the cowl top panel (1) Cowl Panel Cover - Removal





50. Lower air cleaner housing assembly (1) aligning the locating pin (3).
51. Tighten retaining bolt (2) securely.
52. Connect the air duct at the air cleaner cover and tighten the clamp securely.





53. Install the engine cover (1).

54. Fill the engine with oil
55. Fill the cooling system Service and Repair
56. Connect the negative battery cable.
57. Start the engine and inspect for leaks.
58. Road test the vehicle.