Engine Assembly, Installation

ENGINE ASSEMBLY

COMPONENTS:

INSTALLATION
1. INSTALL KNOCK SENSOR
2. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
a. Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive: Part No. 08833-00080 THREE BOND 1344, LOCTITE 242 or equivalent.
b. Using a deep socket wrench 24 mm, install the oil pressure switch.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
3. INSTALL THERMOSTAT
4. INSTALL WATER INLET
a. Install the water inlet (TMC made).
5. INSTALL WATER INLET PIPE
a. Install the water inlet pipe (TMC made).
6. INSTALL WATER INLET
a. Install the water inlet (TMMWV made).
7. INSTALL COMPRESSOR MOUNTING BRACKET NO. 1
8. INSTALL GENERATOR BRACKET NO. 1
Torque: 58 Nm (591 kgf-cm, 43 ft. lbs.)
9. INSTALL PUMP BRACKET
Torque: 32 Nm (326 kgf-cm, 24 ft. lbs.)
10. INSTALL ENGINE MOUNTING BRACKET RH
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)
11. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY No. 2
12. INSTALL MANIFOLD STAY No. 2
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
13. INSTALL EXHAUST MANIFOLD HEAT INSULATOR No. 2
14. INSTALL MANIFOLD CONVERTER INSULATOR NO. 3
15. INSTALL IGNITION COIL ASSEMBLY
16. INSTALL WATER OUTLET
17. INSTALL INTAKE MANIFOLD
18. INSTALL INTAKE AIR SURGE TANK
19. INSTALL EMISSION CONTROL VALVE SET
20. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY
SST 09213-54015 (91651-60855), 09330-00021
21. INSTALL ENGINE MOUNTING BRACKET RR
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
22. INSTALL AUTOMATIC TRANSMISSION W/TRANSFER (for 4WD)
23. INSTALL TRANSFER STIFFENER PLATE RH (for 4WD)
24. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD)
25. INSTALL ENGINE MOUNTING BRACKET FR
26. INSTALL STARTER ASSEMBLY
27. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
28. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD)
29. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD)
30. INSTALL FRONT FRAME ASSEMBLY

a. Install the engine mounting insulator RH and LH with the 2 nuts.
Torque: 95 Nm (969 kgf-cm, 70 ft. lbs.)

b. Install the engine mounting insulator FR with the nut.
Torque: 87 Nm (887 kgf-cm, 64 ft. lbs.)

c. Install the engine mounting insulator RR with the 2 bolts.
Torque: 75 Nm (765 kgf-cm, 55 ft. lbs.)
31. INSTALL POWER STEERING LINK ASSEMBLY (for 4WD)
Torque: 70 Nm (714 kgf-cm, 52 ft. lbs.)
32. INSTALL STABILIZER BAR FRONT (for 4WD)
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)
33. INSTALL VANE PUMP ASSEMBLY

a. Temporarily tighten the bolt.
b. Install the adjusting strut to the engine mounting bracket RH with the bolt.
Torque: 43 Nm (439 kgf-cm, 32 ft. lbs.)

c. Connect the PS pressure tube with the 3 nuts.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)
34. INSTALL VANE PUMP V BELT
35. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
36. INSTALL MANIFOLD STAY
37. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1
38. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

a. Set the engine assembly with transaxle on the engine lifter.
b. Install the engine assembly to the vehicle.
c. Install the frame side rail plate RH and LH with the 6 bolts and 2 nuts.
Torque:
Bolt A 85 Nm (867 kgf-cm, 63 ft. lbs.)
Bolt B 32 Nm (326 kgf-cm, 24 ft. lbs.)
Nut C 32 Nm (326 kgf-cm, 24 ft. lbs.)

d. Install the front suspension member brace rear RH and LH with the 6 bolts and 2 nuts.
Torque:
Bolt A 85 Nm (867 kgf-cm, 63 ft. lbs.)
Bolt B 32 Nm (326 kgf-cm, 24 ft. lbs.)
Nut C 32 Nm (326 kgf-cm, 24 ft. lbs.)
39. INSTALL HEIGHT CONTROL SENSOR LINK SUB-ASSEMBLY FRONT
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
a. w/air suspension
40. CONNECT STEERING INTERMEDIATE SHAFT SUBASSEMBLY
41. INSTALL FRONT AXLE ASSEMBLY LH
42. INSTALL FRONT AXLE ASSEMBLY RH

HINT: Perform the same procedure as above on the opposite side.

43. INSTALL FRONT SUSPENSION ARM SUBASSEMBLY LOWER NO. 1 LH
44. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 RH

HINT: Perform the same procedure as above on the opposite side.

45. CONNECT TIE ROD END SUB-ASSEMBLY LH
46. CONNECT TIE ROD END SUB-ASSEMBLY RH

HINT: Perform the same procedure as above on the opposite side.

47. INSTALL SPEED SENSOR FRONT LH
48. INSTALL SPEED SENSOR FRONT RH

HINT: Perform the same procedure as above on the opposite side.

49. INSTALL FRONT AXLE HUB LH NUT
50. INSTALL FRONT AXLE HUB RH NUT

HINT: Perform the same procedure as above on the opposite side.

51. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
52. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT: Perform the same procedure as above on the opposite side.

53. INSTALL EXHAUST PIPE SUPPORT BRACKET NO. 1
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)
54. INSTALL EXHAUST PIPE ASSEMBLY FRONT
55. INSTALL EXHAUST PIPE SUB-ASSEMBLY FRONT NO. 3
56. INSTALL PROPELLER SHAFT (for 4WD)
57. CONNECT FUEL PIPE SUB-ASSEMBLY NO. 1
58. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY
59. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
60. INSTALL GENERATOR BELT ADJUSTING BAR
61. INSTALL GENERATOR BRACKET No. 2
62. INSTALL ENGINE MOUNTING STAY No. 2 RH
63. INSTALL ENGINE MOVING CONTROL ROD
64. INSTALL GENERATOR ASSEMBLY
65. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1
66. INSPECT DRIVE BELT DEFLECTION AND TENSION
67. INSTALL AIR CLEANER INLET NO. 1
68. INSTALL AIR CLEANER BRACKET
69. INSTALL AIR CLEANER CASE
70. INSTALL AIR CLEANER INLET No. 2
71. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

72. CONNECT VACUUM HOSE
73. INSTALL V-BANK COVER SUB-ASSEMBLY
74. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER
75. INSTALL WINDSHIELD WIPER LINK ASSEMBLY
76. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
77. INSTALL FR WIPER ARM LH
78. INSTALL FR WIPER ARM RH
79. INSTALL FRONT WHEELS
80. ADD TRANSFER OIL (for 4WD)
81. INSPECT TRANSFER OIL (for 4WD)
82. ADD AUTOMATIC TRANSAXLE FLUID
83. ADD ENGINE OIL
84. ADD ENGINE COOLANT
85. ADD POWER STEERING FLUID
86. BLEED POWER STEERING FLUID
87. INSPECT AUTOMATIC TRANSAXLE FLUID
88. CHECK FOR ENGINE OIL LEAKS
89. CHECK FOR ENGINE COOLANT LEAKAGE
90. CHECK POWER STEERING FLUID LEAKAGE
91. INSPECT FUEL LEAKAGE
92. CHECK FOR EXHAUST GAS LEAKAGE
93. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
94. INSPECT STEERING WHEEL CENTER POINT
95. INSPECT IGNITION TIMING
SST 09843-18040
96. INSPECT ENGINE IDLE SPEED
SST 09843-18040
97. INSPECT CO/HC
98. CHECK ABS SPEED SENSOR SIGNAL