Specifications

(75) Install the lower radiator hose on the radiator
(Fig. 35).
(76) Install the transmission fluid cooler lines on
the radiator (Fig. 35).
(77)
Install both of the front splash shields (Fig. 35).
(78) Lower the vehicle on the hoist.
(79) Fill the cooling system and close the system
vent. Refer to Group 7, Cooling System for the proce-
dure.
(80) With assistance from another person, install
the hood.
NOTE: Use the previously marked hinge locations
for alignment reference.
(81) Install the hood retaining bolts. Torque the
bolts to 40 N·m (30 ft. lbs.).
(82) Fill the power steering system fluid. Refer to
Group 19, Steering – Power Steering Pump-Initial
operation for the procedure.
(83) Fill the transmission fluid. Refer to Group 21,
Transmission and Transfer Case for the procedure.
(84) Remove both fender covers.
(85) Connect the engine compartment lamp.
(86) Connect the negative battery cable.
(87)
Check the engine oil level before engine start up.
EXHAUST / INTAKE MANIFOLD
REMOVAL
NOTE: The 3.1L Turbo Diesel Engine Exhaust Man-
ifold must be removed first in order to remove the
intake manifold. Because these manifolds utilize a
single sealing gasket at the cylinder head if either
manifold requires service both manifolds must be
removed.
(1) Disconnect the negative battery cable.
(2) Raise the vehicle on a hoist.
WARNING: DO NOT LOOSEN THE RADIATOR VENT
OR DRAINCOCK WITH THE SYSTEM HOT AND
PRESSURIZED. SERIOUS BURNS FROM COOLANT
CAN OCCUR
(3) Drain the cooling system. Refer to Group 7,
Cooling System for procedure.
(4) Remove the exhaust system inlet pipe retaining
bolts (Fig. 36).
(5) Disconnect the turbocharger oil return hose
from the turbocharger.
(6) Lower the vehicle on the hoist.
(7) Remove the intercooler inlet hose from the
vehicle (Fig. 37).
(8) Disconnect the breather hose from the fresh air
inlet tube (Fig. 37).
(9) Unclip the air filter cover and remove the fresh
air inlet tube from the turbocharger (Fig. 37).
Remove the assembly from the vehicle.
(10) Remove the EGR vacuum supply hose from
the EGR valve (Fig. 38).
(11) Disconnect the heater core coolant supply
lines from the engine assembly (Fig. 38).
(12) Unclip the wire harness from the coolant sup-
ply lines (Fig. 38).
(13) Remove the (2) EGR valve / coolant supply
line retaining bolts (Fig. 38).
(14) Remove the coolant supply line support
bracket bolt from the water pump housing.
Fig. 35 Transmission Fluid Cooler Lines
Fig. 36 Exhaust System Inlet Pipe Retaining Bolts
9 - 24 ENGINE WJ
REMOVAL AND INSTALLATION (Continued)