Dodge ZB 2005 Service Manual page 677

9 - 16 ENGINE
ENGINE - 8.3L (Continued)
(42) Attach an appropriate chain to engine lifting
brackets. Remove engine with an engine hoist (Fig.
14).
Fig. 14 Engine Removal/Installation
1 - SUITABLE LIFTING CHAIN
2 - SPECIAL TOOLS 9057 (ENGINE LIFT BRACKETS)
INSTALLATION - ENGINE ASSEMBLY
(1) Attach engine hoist and lower the engine into
engine compartment (Fig. 14).
(2) Align left and right engine mounts and install
mounting nuts (Fig. 10). Tighten nuts to 102 N·m (75
ft. lbs.).
(3) Remove engine hoist and engine lifting brack-
ets/chain.
(4) Raise vehicle on hoist.
(5) Connect ground strap to right side engine
mount.
(6) Install transmission.
(7) Slide transmission back into the clutch and
seat against the bell housing.
(8) Install transmission bolts (Fig. 9) and tighten
bolts to:
• 7/16 Transmission bolts and washers - 68 N·m
(50 ft. lbs.)
• Transmission to top of engine - 41 N·m (30 ft.
lbs.)
• Transmission to oil pan - 30 N·m (22 ft. lbs.)
(9) Install transmission mount and crossmember
(Fig. 8).
(10) Connect transmission electrical connectors.
(11) Connect hydraulic clutch line.
(12) Install drive shaft.
(13) Connect oil cooler lines (Refer to 9 - ENGINE/
LUBRICATION/OIL COOLER & LINES - STAN-
DARD PROCEDURE).
(14) Install fasteners securing A/C line to oil pan.
(15) Install lower radiator hose.
(16) Connect starter electrical connections.
(17) Connect exhaust system at left and right
exhaust manifolds using NEW V-Band clamps.
Tighten V-Band clamps to 11 N·m (100 in. lbs.).
(18) Install left and right catalytic converter sup-
port hanger bracket bolts (Fig. 7). Torque bolts to 28
N·m (250 in. lbs.).
(19) Install under body stone shields.
(20) Lower vehicle.
(21) Install left and right side sill panels (Refer to
23 - BODY/EXTERIOR/ROCKER PANEL COVER -
INSTALLATION) (Fig. 6).
(22) Install gear shift lever and gear shifter trim
bezel.
(23) Connect A/C clutch electrical connector.
(24) Connect A/C lines to A/C compressor.
(25) Connect fuel line and accelerator cable.
(26) Connect brake booster vacuum hose. Connect
evaporative emission hoses.
(27) Connect PCM connectors and ground wire at
left side frame rail.
(28) Connect coolant bottle inlet hose to thermo-
stat housing.
(29) Connect heater hoses to engine.
(30) Install and connect generator.
(31) Install power steering pump.
(32) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
INSTALLATION).
(33) Install upper radiator hose.
(34) Install front strut tower to tower brace (Refer
to 23 - BODY/EXTERIOR/FRONT STRUT TOWER
TO TOWER BRACE - INSTALLATION) (Fig. 5).
(35) Install cowl cover (Refer to 23 - BODY/EXTE-
RIOR/COWL COVER - INSTALLATION).
(36) Install windshield wiper arms (Refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER ARMS -
INSTALLATION).
(37) Evacuate and recharge air conditioning sys-
tem (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/REFRIGERANT
PROCEDURE).
(38) Fill cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE - FILLING
COOLING SYSTEM).
(39) Install NEW oil filter.
(40) Fill engine crankcase with proper oil to cor-
rect level (Refer to LUBRICATION & MAINTE-
NANCE/FLUID TYPES - SPECIFICATIONS).
DRIVE/DRIVE BELT
- STANDARD
ZB
-