Part 2

ENGINE ASSEMBLY

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5) (for 2WD):

COMPONENTS (Part 6) (For 4WD):

COMPONENTS (Part 7) (for 2WD):

COMPONENTS (Part 8) (for 4WD):

COMPONENTS (Part 9) (for 2WD):

COMPONENTS (Part 10) (for 4WD):

COMPONENTS (Part 11) (for 2WD):

COMPONENTS (Part 12) (for 4WD):

COMPONENTS (Part 13) (for 2WD):

COMPONENTS (Part 14) (for 4WD):

COMPONENTS (Part 15):

COMPONENTS (Part 16):

COMPONENTS (Part 17):

COMPONENTS (Part 18):

COMPONENTS (Part 19):

COMPONENTS (Part 20):

COMPONENTS (Part 21):

COMPONENTS (Part 22):

INSTALLATION Continued

52. INSTALL ENGINE AND TRANSMISSION (for 4WD)
(a) Operate the engine lifter, then install the engine to the vehicle.

(b) Install the engine and transmission with crossmember with the 6 bolts and 2 nuts.
Torque:
167 N*m (1703 kgf*cm, 123 ft.*lbf) for nut A
165 N*m (1683 kgf*cm, 122 ft.*lbf) for bolt B
50 N*m (510 kgf*cm, 37 ft.*lbf) for bolt C

(c) Install the engine rear mounting member with the 4 bolts.
Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf)

53. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for 2WD)
54. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for 4WD)
55. INSTALL FRONT DRIVE SHAFT LH (for 4WD)
56. INSTALL FRONT DRIVE SHAFT RH (for 4WD)
57. INSTALL FRONT LOWER BALL JOINT ASSEMBLY LH (for 2WD)
58. INSTALL FRONT LOWER BALL JOINT ASSEMBLY RH (for 2WD)

HINT: Perform the same procedure as for the LH side.

59. INSTALL FRONT LOWER BALL JOINT LH (for 4WD)
60. INSTALL FRONT LOWER BALL JOINT RH (for 4WD)

HINT: Perform the same procedure as for the LH side.

61. INSTALL TIE ROD ASSEMBLY LH (for 2WD)
62. INSTALL TIE ROD ASSEMBLY RH (for 2WD)

HINT: Perform the same procedure as for the LH side.

63. INSTALL TIE ROD ASSEMBLY LH (for 4WD)
64. INSTALL TIE ROD ASSEMBLY RH (for 4WD)

HINT: Perform the same procedure as for the LH side.

65. TEMPORARILY INSTALL FRONT SHOCK ABSORBER ASSEMBLY LH (for 2WD)
(a) Insert the bolt from the rear of the vehicle, and set the front shock absorber lower side on the front suspension lower arm.
(b) Temporarily tighten the nut while holding the bolt.

66. TEMPORARILY INSTALL FRONT SHOCK ABSORBER ASSEMBLY RH (for 2WD)

HINT: Perform the same procedure as for the LH side.

67. INSTALL FRONT SHOCK ABSORBER ASSEMBLY LH (for 4WD)
(a) Install the front shock absorber to the bracket lower with the bolt.
Torque: 48 N*m (489 kgf*cm, 35 ft.*lbf)

68. INSTALL FRONT SHOCK ABSORBER ASSEMBLY RH (for 4WD)

HINT: Perform the same procedure as for the LH side.

69. CONNECT HEIGHT CONTROL SENSOR LINK LH (for 2WD)
70. CONNECT HEIGHT CONTROL SENSOR LINK RH (for 2WD)

HINT: Perform the same procedure as for the LH side.

71. CONNECT HEIGHT CONTROL SENSOR LINK LH (for 4WD)
72. CONNECT HEIGHT CONTROL SENSOR LINK RH (for 4WD)

HINT: Perform the same procedure as for the LH side.

73. INSTALL STEERING SLIDING YOKE SUBASSEMBLY (for 2WD)
(a) Align the matchmarks of the No. 2 intermediate shaft and steering sliding yoke.
(b) Temporarily install the bolt (B).
(c) Tighten the 2 bolts (A) and (B).
Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf)

74. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for 4WD)

(a) for Exterior Side:
(1) Align the matchmarks of the No. 2 intermediate shaft and power steering link.

(b) for Interior Side:
(1) Align the matchmarks of the No. 2 intermediate shaft and steering column.

(d) for Interior Side:
(1) Install the bolt.
Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf)
(2) Install the clamp to the steering column hole cover.

75. INSTALL INSTRUMENT PANEL NO. 1 UNDER COVER SUB-ASSEMBLY (for 4WD)
76. INSTALL NO. 1 AIR DUCT (for 4WD)
77. INSTALL FRONT SPEED SENSOR LH (for 4WD)
78. INSTALL FRONT SPEED SENSOR RH (for 4WD)

HINT: Perform the same procedure as for the LH side.

79. INSTALL FRONT AXLE HUB NUT LH (for 4WD)
80. INSTALL FRONT AXLE HUB NUT RH (for 4WD)

HINT: Perform the same procedure as for the LH side.

81. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (for 4WD)
82. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 2WD)
83. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD)
84. INSTALL FRONT FLOOR NO. 1 HEAT INSULATOR
85. INSTALL FRONT EXHAUST PIPE ASSEMBLY
86. INSTALL HEATED OXYGEN SENSOR (for Sensor 2)
(a) Install the heated oxygen sensor.

87. INSTALL FRONT FLOOR BRACE CENTER

88. INSTALL FRONT SUSPENSION MEMBER PROTECTOR LOWER (for 2WD)
(a) Install the protector with the 4 bolts.
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

89. INSTALL GENERATOR WITH CLUTCH PULLEY
90. INSTALL COOLER COMPRESSOR ASSEMBLY (for 2WD)
91. INSTALL DISCHARGE HOSE SUB-ASSEMBLY (for 2WD)
92. INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE (for 2WD)
93. TEMPORARILY TIGHTEN COOLER COMPRESSOR ASSEMBLY (for 4WD)
94. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY (for 4WD)
95. INSTALL OIL FILTER BRACKET (for 4WD)
96. TIGHTEN COOLER COMPRESSOR ASSEMBLY (for 4WD)
97. INSTALL DISCHARGE HOSE SUB-ASSEMBLY (for 4WD)
98. INSTALL NO. 1 COOLER REFRIGERANT SUCTION HOSE (for 4WD)
99. INSTALL V-RIBBED BELT

100. INSTALL ENGINE UNDER COVER AIR GUIDE BRACKET (for 2WD)
(a) Install the bracket with the 2 bolts.
Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf)

101. CONNECT NO. 3 FUEL HOSE SUB-ASSEMBLY
(a) Connect the fuel hose to the pipe.

102. CONNECT FUEL TUBE SUB-ASSEMBLY
(a) Connect the fuel tube LH and RH side.

103. CONNECT ENGINE WIRE

(a) for Automatic Transmission Side:
(1) Install the ground cable with the nut to the RH side.
Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf)

For Power Steering Link Side (for 2WD):

(b) for Power Steering Link Side (for 2WD):
(1) Install the ground cable with the bolt (A) and (B).
Torque:
8.0 N*m (82 kgf*cm, 71 in.*lbf) for bolt A
5.0 N*m (51 kgf*cm, 44 in.*lbf) for bolt B
(2) Connect the 2 connectors (C).
(3) Connect the connector to the power steering link and securely lock the connector (D).
(4) Attach the 2 clamps (E).

For Power Steering Link Side (for 4WD):

(c) for Power Steering Link Side (for 4WD):
(1) Install the ground cable with the bolt (A) and (B).
Torque:
5.0 N*m (51 kgf*cm, 44 in.*lbf) for bolt A
8.0 N*m (82 kgf*cm, 71 in.*lbf) for bolt B
(2) Connect the 2 connectors (C).
(3) Connect the connector to the power steering link and securely lock the connector (D).
(4) Attach the 2 clamps (E).
(5) Connect the wire harness bracket to the frame with the bolt (G).
Torque: 8.0 N*m (82 kgf*cm, 71 in.*lbf)
(d) for RH Side:
(1) Install the battery positive (+) cable to the battery positive terminal with the nut as shown in the illustration (A) below.
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
(2) Connect the cable with the clamp as shown in the illustration (A) below.
(3) Install the No. 1 engine wire with the nut as shown in the illustration (B).
Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
(4) Install the No. 1 relay block cover.
(5) Install the wire harness to the wire harness cover, and attach them as shown in the illustration (C).
(6) Install the No. 2 ground cable with the bolt as shown in the illustration (C).
Torque: 9.0 N*m (92 kgf*cm, 80 in.*lbf)
(7) Install the No. 4 relay block with the 2 bolts as shown in the illustration (D).
Torque: 13 N*m (133 kgf*cm, 10 ft.*lbf)
(e) for LH Side:
(1) Connect the No. 2 ground cable with the bolt as shown in the illustration (E).
Torque: 8.8 N*m (90 kgf*cm, 78 in.*lbf)
(2) Connect the ECM connectors, and set the connector holder to the ECM box as shown in the illustration (F).

(3) Connect the ECM's harness with the clamp as shown in the illustration (F).
(4) Install the ECM cover with the 3 bolts.
Torque: 5.5 N*m (56 kgf*cm, 49 in.*lbf)
(f) for Engine Bank 1 Side:
(1) Install the ground cable with the bolt as shown in the illustration (G).
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)
(2) Connect the ground cable with the clamp as shown in the illustration (G).

104. CONNECT UNION TO CHECK VALVE HOSE

105. CONNECT HEATER WATER OUTLET HOSE A

106. CONNECT HEATER WATER INLET HOSE A

107. CONNECT RADIATOR RESERVOIR HOSE
108. CONNECT NO. 1 RADIATOR HOSE
109. CONNECT NO. 2 RADIATOR HOSE

110. CONNECT PURGE LINE HOSE

111. INSTALL AIR CLEANER CASE
(a) Install the case with the 3 bolts.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)
(b) Connect the clamp.

112. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE
113. CONNECT NO. 2 VENTILATION HOSE

114. INSTALL NO. 1 AIR CLEANER INLET
(a) Install the air cleaner inlet with the bolt.
Torque: 5.0 N*m (51 kgf*cm, 44 in.*lbf)

115. ADJUST SHIFT LEVER POSITION (for 2WD)
116. ADJUST SHIFT LEVER POSITION (for 4WD)
117. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
118. INSPECT FOR FUEL LEAK
119. ADD ENGINE OIL
120. ADD DIFFERENTIAL OIL (for 4WD)
121. ADD ENGINE COOLANT
122. INSPECT FOR OIL LEAK
123. INSPECT FOR COOLANT LEAK
124. INSPECT FOR EXHAUST GAS LEAK
125. INSPECT ENGINE OIL LEVEL
126. INSPECT ENGINE COOLANT LEVEL
127. CHARGE REFRIGERANT
128. INSPECT FOR LEAKAGE OF REFRIGERANT
129. INSPECT IGNITION TIMING
130. INSPECT IDLE SPEED
131. INSPECT CO/HC

132. INSTALL V-BANK COVER SUB-ASSEMBLY
(a) Attach the 3 clips to install the engine cover.

NOTICE:
^ Be sure to engage the clips securely.
^ Do not apply excessive force or do not hit the cover to engage the clips. This may cause the cover to break.

133. INSTALL ENGINE ROOM SIDE COVER LH
(a) Install the side cover with the 3 clips.

134. INSTALL ENGINE ROOM COVER SIDE RH
(a) Install the side cover with the 2 clips.

135. INSTALL COOL AIR INTAKE DUCT SEAL
(a) Install the intake duct seal with the 7 clips.

136. STABILIZE SUSPENSION
137. TIGHTEN FRONT SHOCK ABSORBER ASSEMBLY LH (for 2WD)
138. TIGHTEN FRONT SHOCK ABSORBER ASSEMBLY RH (for 2WD)

HINT: Perform the same procedure as for the LH side.

139. TIGHTEN FRONT SHOCK ABSORBER ASSEMBLY LH (for 4WD)
140. TIGHTEN FRONT SHOCK ABSORBER ASSEMBLY RH (for 4WD)

HINT: Perform the same procedure as for the LH side.

141. INSTALL AIR GUIDE PLATE OUTSIDE RH
142. INSTALL FRONT FLOOR COVER CENTER LH (for 4WD)
143. INSTALL NO. 2 ENGINE UNDER COVER (for 2WD)
(a) Install the under cover with the 4 screws, 2 grommets and 2 spacers.

144. INSTALL REAR ENGINE UNDER COVER LH (for 2WD)
145. INSTALL REAR ENGINE UNDER COVER RH (for 2WD)
146. INSTALL ENGINE UNDER COVER (for 2WD)
147. INSTALL ENGINE UNDER COVER (for 4WD)
148. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
149. INSTALL FRONT WHEELS
Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf)

150. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(a) Check and adjust the front wheel alignment.

151. PERFORM RESET MEMORY (for 2WD)
(a) Perform the RESET MEMORY procedures (A/T initialization). Initialization

152. PERFORM RESET MEMORY (for 4WD)
(a) Perform the RESET MEMORY procedures (A/T initialization). Initialization

153. PERFORM INITIALIZATION
(a) Perform initialization. Repair Instruction - Initialization

NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.