INSTALLATION
ENGINE - 2.8L DIESEL
1. Install engine assembly and align with the transmission.
NOTE: For vehicle equipped with a manual transmission, Install the transmission.
2. Raise and support the vehicle.
3. Install accessable engine to transmission housing bolts. tighten bolts to 68 N·m (50 ft. lbs.).
4. Connect oil pressure sensor, located between the engine block and the turbocharger.
5. Connect crankshaft position sensor, located on the right rear of the engine.
6. Install right side engine mount on the engine block.
7. Disconnect lifting device from the engine assembly.
8. Raise and support the vehicle.
9. Install all transmission to engine retaining bolts.
10. Install exhaust inlet pipe and retaining bolts.
11. Install chassis ground wire above starter mounting location on the engine block.
12. Install starter motor on the engine.
13. Install oil filter and cooler assembly.
14. Lower vehicle.
15. Install oil cooler adapter.
16. Install coolant elbow and retaining bolts and connect the hoses leading from it.
17. Trace engine wiring and connect electrical connectors and tie straps one at a time until all wiring is connected on engine assembly.
18. Install low side refrigerant line.
19. Install generator on the engine (Refer to 8 - ELECTRICAL/CHARGING/GENERATOR - INSTALLATION).
20. Connect heater core inlet and outlet hoses at heater core.
21. Connect four large electrical connectors near rear of the right front fenderwell.
22. Install engine cover mounting bracket and retaining bolts.
23. Accessing bolts through the pump pulley, install the power steering pump and retaining bolts.
24. Install accessory drive belt (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION).
25. Install coolant reservoir and connect hoses.
26. Install coolant reservoir retaining nuts.
27. Install high side refrigerant line on compressor.
28. Install charge air cooler hose on intake manifold.
29. Install cooling module assembly in the engine bay.
30. Install power steering cooler and retaining bolts and clip the air deflectors on both sides of the radiator (cooling module) assembly.
31. Install condenser assembly and retaining bolts.
32. Install low side refrigerant line and retaining nut.
33. Connect coolant reservoir hose on radiator.
34. Connect engine coolant hoses on engine.
35. Connect charge air cooler hoses on charge air cooler.
36. Install fan shroud with cooling fan assembly inside the shroud and install the shroud retaining bolts.
37. Connect cooling fan and fan drive viscous clutch assembly to fan support.
38. Install high side refrigerant line and retaining nut.
39. Install upper radiator support bracket and retaining bolts.
40. Connect high side refrigerant line on the upper radiator support bracket.
41. Charge refrigerant system (Refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE).
42. Install air filter assembly.
43. Install engine cover (Refer to 9 - ENGINE COVER - REMOVAL).
44. Install engine oil fill cap.
45. Fill cooling system (Refer to 7 - COOLING/ENGINE/COOLANT - STANDARD PROCEDURE).
46. With assistance from another person, install hood assembly on the vehicle.
47. Connect under hood lamp on the hood assembly.
48. Connect negative battery cable.
ENGINE COVER
1. Align engine cover (2) with mounting bracket (1). Push down firmly on all four corners of engine cover to snap in place.
2. Install oil fill cap.