Installation

Engine





Special Tool(s)

Installation

1. NOTE: Align the engine-to-transmission dowels before installing engine to transmission bolts.

Position the engine in the vehicle.





2. Remove the special tool.
3. Raise and support the vehicle.





4. Install the lower five transmission-to-engine bolts.





5. Install the torque converter-to-flexplate nuts.





6. Install the cylinder block opening cover.





7. Install the flexplate inspection cover.





8. Position and install and the LH engine mount bolt.





9. Position and install the RH engine mount bolt.
10. Install the starter motor.
11. Install the RH exhaust manifold studs.





12. Install and tighten the four nuts.





13. Position the lower radiator hose on the oil filter adapter and secure the hose clamp.





14. NOTE: Only three bolts are required for installation.

Install the bolts.





15. Install the oil bypass filter.





16. Install the oil pressure switch.





17. Connect the oil pressure switch electrical connector.





18. Install the transmission fluid cooler tubes in the clip.





19. Install the AC line (muffler) bracket.





20. Connect the heated exhaust gas oxygen sensor electrical connectors.





21. NOTE: Lubricate the O-ring seals with transmission fluid.

Install the transmission fluid filler tube and nut.
22. Install the AC compressor.





23. NOTE: Do not reuse the O-ring seal. On Windsor engines, slide the water heater tube forward over the new O-ring seal.

Lubricate the O-ring seal with engine coolant.





24. Position the transmission wiring bracket and install the upper two transmission-to-engine bolts.
25. Connect the transmission wiring harness connectors.
26. Connect the two heater hoses at the heater core.





27. Install the connector bracket.





28. Connect the starter relay electrical connections.





29. Install the 38-pin connector in the bracket.





30. Install the connector bracket cover.





31. Connect the electrical connector and install it on the bracket.





32. NOTE: Battery removed for clarity.

Connect the 38-pin, 42-pin and 16-pin electrical connectors.





33. Position the exhaust manifold to Exhaust Gas Recirculation (EGR) valve tube and hand-tighten the lower fitting.





34. Position the power steering reservoir and install the two lower bolts.





35. Connect the climate control vacuum connector.





36. Connect the generator electrical connections and position the generator aside.
37. Install the AC condenser.





38. Position the Engine Air Cleaner (ACL) in the vehicle and connect the Mass Air Flow (MAF) sensor electrical connector.





39. Install the ACL.
40. Install the hood.
41. Install the intake manifold.
42. Fill all fluids to the correct levels.

43. CAUTION: The off pump must be primed prior to starting the engine.

Start the engine and check for leaks. Stop the engine and recheck the fluid levels.
44. Recharge the AC system.