Installation
1. Install engine and transmission assembly in vehicle.
(a) Attach the engine hoist chain to the engine hangers.
(b) Lower the engine and transmission assembly into the engine compartment.
(c) Insert the stud bolts of the front engine mounting insulators into the stud bolt holes of the frame.
(d) Temporarily install the 2 nuts holding the engine front mounting insulators to the frame crossmember.
(e) Keep the engine level with a jack.
(f) Remove the hoist chain.
2. Install frame crossmember.
(a) Temporarily install the crossmember to the engine rear mounting insulator with the 2 nuts.
(b) Install the 8 bolts holding the crossmember to the frame.
Torque: 61 Nm (45 ft. lbs.)
(c) Tighten the 2 nuts holding the crossmember to the engine rear mounting insulator.
Torque: 74 Nm (54 ft. lbs.)
3. Tighten nuts holding engine front mounting insulators to frame.
Torque: 74 Nm (54 ft. lbs.)
4. Connect ground strap to heat insulator.
5. Install front exhaust pipe.
(a) Install 2 new gaskets and the front exhaust pipe with the 4 nuts.
Torque: 63 Nm (46 ft. lbs.)
(b) Install the No. 1 support bracket with the 2 bolts.
Torque: 24 Nm (17 ft. lbs.)
(c) Connect the clamp and tighten the clamp bolt.
Torque: 19.5 Nm (14 ft. lbs.)
(d) Connect the front exhaust pipe to the rear Three-Way Catalytic Converter (TWC) with a new gasket, 2 bolts and 2 nuts.
Torque: 46 Nm (34 ft. lbs.)
6. Install transfer shift lever.
(a) Install the shift lever and hose clamp with the 4 bolts.
Torque: 18 Nm (13 ft. lbs.)
(b) Connect the shift rod and install the pin.
(c) Install the transfer shift lever boot and transmission shift lever assembly with the 10 bolts.
Torque: 5.4 Nm (48 inch lbs.)
(d) Connect the 3 connectors to the transmission shift lever assembly.
(e) Install the console box with the 3 bolts.
(f) Connect the pattern select switch connector.
(g) Install the console with the 4 screws.
(h) Install the transfer shift lever knob.
(i) Shift the shift lever to N position.
(j) Fully turn the control shaft lever back and return 2 notches. It is now in neutral position.
(k) Connect the transmission control rod with the nut.
Torque: 13 Nm (9 ft. lbs.)
7. Install front and rear propeller shafts.
Differential Side:
(a) Align the matchmarks on the flanges and connect the flanges with the 4 bolts and nuts.
(b) Torque the bolts and nuts.
Torque:
Front shaft: 74 Nm (54 ft. lbs.)
Rear shaft: 88 Nm (65 ft. lbs.)
Transfer Side:
(a) Align the matchmarks on the flanges and connect the flanges with the 4 nuts.
(b) Torque the nuts.
Torque:
Front shaft: 74 Nm (54 ft. lbs.)
Rear shaft: 88 Nm. (65 ft. lbs.)
8. Install stabilizer bar.
(a) Temporarily install the stabilizer bar to the axle housing with the bolt and nut.
(b) Connect the stabilizer bar with the 2 bolts.
Torque: 18 Nm (13 ft. lbs.)
(c) Bounce the vehicle up and down to stabilize the suspension.
(d) Torque the bolt and nut holding the stabilizer bar to the axle housing.
Torque: 25 Nm (19 ft. lbs.)
9. Connect engine wire to cabin.
(a) Push in the engine wire through the cowl panel.
(b) Connect these connectors:
(1) 3 connectors to Engine Control Module (ECM).
(2) 2 connectors to cowl wire.
(c) Connect the A/C amplifier with the screw.
(d) Install the speaker panel with the screw.
(e) Install the glove compartment door with the 2 screws.
10. Connect Power Steering (PS) return hose.
Connect the return hose to the PS reservoir tank.
11. Connect PS pressure hose.
Connect the PS pressure hose with 2 new gaskets and the union bolt.
Torque: 56 Nm (42 ft. lbs.)
12. Install radiator pipe.
Connect the No. 2 radiator hose to the water inlet.
Install the 2 nuts holding the radiator pipe to the No. 1 oil pan.
Torque: 21 Nm (15 ft. lbs.)
13. Install A/C compressor and bracket.
(a) Install the A/C compressor bracket with the 5 bolts.
Torque: 37 Nm (27 ft. lbs.)
(b) Install the A/C compressor with the 4 bolts.
Torque: 25 Nm (18 ft. lbs.)
(c) Install and adjust the drive belt.
14. Connect wires and connectors.
Connect these wires and connectors:
- 2 heated oxygen sensor connectors.
- Data Link Connector (DLC)1 clamp.
- 2 oil pressure gauge connectors.
- Generator wire and connector.
- Connector on intake manifold to fender apron.
- High tension cord to ignition coil.
- Ground strap to No. 1 engine hanger.
- Ground strap to air intake chamber.
- Starter wire.
- Ground cable to cylinder block.
15. Connect fuel hoses.
(a) Connect the fuel inlet hose to the fuel filter with 2 new gaskets and the union bolt.
Torque: 29 Nm (22 ft. lbs.)
(b) Connect the fuel return hose.
16. Connect Evaporative Emission (EVAP) hose.
17. Connect brake booster vacuum hose.
18. Connect heater valve and engine wire to cowl panel.
(a) Connect the heater valve with the 2 bolts.
(b) Connect the engine wire and ground strap with the 2 bolts.
19. Connect heater hoses.
20. Connect accelerator cable to throttle body.
21. Connect cruise control actuator cable to throttle body.
22. Install air cleaner case.
23. Install air cleaner hose and cap.
24. Connect oil cooler hose to oil cooler pipe.
25. Install radiator. Refer to Cooling System.
26. Install radiator grille.
Install the radiator grille with the 5 screws and clip.
27. Install battery tray and battery.
(a) Install the battery tray with the 5 bolts.
(b) Connect the ground strap with the bolt.
(c) Install the battery and hold-down clamp with the nuts.
(d) Connect the battery cables.
28. Fill with engine oil.
29. Fill radiator with engine coolant.
30. Start engine and check for leaks.
31. Check automatic transmission fluid level.
32. Check ignition timing. Refer to Powertrain Management.
33. Install hood.
34. Perform road test.
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
35. Recheck engine coolant and engine oil levels.