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Engine 2-49
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05745159 19. Remove protective tape from A/C suction/discharge hose adapter and connect it to compressor. Install new seal washers.
Figure 2-61: Suction/Discharge Hose Connection
20. Connect glow relay cable and wires. 21. Position support on back of alternator. Then install gen- erator, mounting bracket, idler pulley, support, and tensioner 22. Position remaining cables for battery installation. 23. Connect heater hoses to water pump and water crossover. Mount idler pulley on generator bracket. 24. Install fan and clutch assembly. 25. Install serpentine belt. 26. Connect air inlet hose to turbocharger. 27. Attach radiator upper hoses and tube to thermostat housing. 28. Connect battery positive cable and solenoid wire to starter motor. 29. Position radiator, shroud, condenser, and oil cooler assembly on frame and between air lift brackets, with aid
NOTE:
Verify that fan-to-shroud clearance is at least 1/4 inch (3.18 mm) at all points around shroud before proceeding. 30. Connect radiator upper and lower hoses. 31. Connect surge tank hose to radiator. 32. Install return lines onto power steering pump. 33. Connect power steering pump return lines to oil cooler. 34. Remove protective wrapping or caps and connect hoses to A/C condenser and oil coolers. Use new O-rings on cooler 35. Install passenger and driver side splash shields. 36. Install battery tray and batteries. Connect positive and negative cables to batteries. 37. Install seals and cover plates on air lift brackets. Notched side of seals face engine. 38. Refill engine cooling system, refill engine crankcase with recommended oil, and top off transmission and power 39. Evacuate A/C system for 30 minutes, and recharge. 40. Leakcheck A/C system. 41. Start and run engine. Bleed injectors at line fittings if necessary. Then stop engine, recheck coolant and lubricant 42. Bleed cooling system with air bleeds on engine and radiator. 43. Test drive vehicle and check for leaks or vibrations.
ENGINE DISASSEMBLY Serpentine Belt Removal
1. Rotate belt tensioner counterclockwise with 1/2 in. drive 2. Slide belt off tensioner pulley and remove belt.
Figure 2-62: Fan and Pulley Removal HOSE ADAPTER COMPRESSOR PORTS SEAL WASHERS CLUTCH FAN PUMP WATER PUMP CRANKSHAFT PULLEY PULLEY BOLT (4) PULLEY SPANNER WRENCH 7-S02-017.2 |