Part 2

ENGINE ASSEMBLY

COMPONENTS:

INSTALLATION (STEPS 61-119)

61. CONNECT HEIGHT CONTROL SENSOR LINK (for 2WD)
a. Connect the height control sensor link and install it with the nut.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)

62. CONNECT HEIGHT CONTROL SENSOR LINK (for 4WD)
a. Connect the height control sensor link and install it with the bolt.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
63. INSTALL TIE ROD ASSEMBLY LH (for 4WD)
64. INSTALL TIE ROD ASSEMBLY RH (for 4WD)

HINT: Install the RH side following the same procedures as for the LH side.

65. INSTALL FRONT AXLE HUB LH NUT (for 4WD)
66. INSTALL FRONT AXLE HUB RH NUT (for 4WD)

HINT: Install the RH side following the same procedures as for the LH side.

67. INSTALL FRONT SPEED SENSOR LH (for 4WD)
68. INSTALL FRONT SPEED SENSOR RH (for 4WD)

HINT: Install the RH side following the same procedures as for the LH side.

69. CONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY (for 2WD)
70. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for 4WD)

71. INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR (for 2WD)

72. CONNECT NO. 3 FUEL HOSE
a. Connect the No. 3 fuel hose and clamp.
73. CONNECT FUEL MAIN TUBE
74. CONNECT ENGINE WIRE

a. Install the bolt, clamp and engine wire No. 3.
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)
b. Connect the ground cable and install it with the bolt.
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)

c. Connect the connector and install the 4 clamps to the body.
d. Connect the wire to the engine room No. 1 junction block. Then, install it with the nut.
Torque: 12 Nm (124 kgf-cm, 9 ft. lbs.)
e. Install the engine room No. 1 relay block cover.
f. Connect the battery positive (+) cable and install it with the nut.
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
g. Connect the ECM connectors.

h. Connect the connector holder.
75. INSTALL ECM COVER
76. CONNECT DISCHARGE HOSE SUB-ASSEMBLY
77. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE

78. CONNECT INLET HEATER WATER HOSE
a. Connect the inlet heater water hose.

79. CONNECT OUTLET HEATER WATER HOSE
a. Connect the outlet heater water hose.

80. CONNECT INLET RADIATOR HOSE
a. Install the clamp and connect the inlet radiator hose.
81. CONNECT OUTLET RADIATOR HOSE
a. Install the clamp and connect the outlet radiator hose.
82. CONNECT RADIATOR RESERVOIR TANK HOSE
a. Install the clamp and connect the reservoir tank hose.

83. CONNECT NO. 2 FUEL VAPOR FEED HOSE
a. Install the clamp and connect the No. 2 fuel vapor feed hose.
84. CONNECT UNION TO CHECK VALVE HOSE
a. Connect the hose to the surge tank.

85. INSTALL AIR CLEANER CASE SUB-ASSEMBLY
a. Install the air cleaner case, clamp and 2 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
86. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

87. INSTALL NO. 1 INLET AIR CLEANER
a. Install the inlet air cleaner with the bolt.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
88. INSTALL PROPELLER SHAFT ASSEMBLY WITH CENTER BEARING
89. INSTALL FRONT EXHAUST PIPE ASSEMBLY
90. ADD FRONT DIFFERENTIAL OIL (for 4WD)
91. ADD ENGINE OIL (for 2WD)
92. ADD ENGINE OIL (for 4WD)
93. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
94. ADD ENGINE COOLANT
95. CHARGE REFRIGERANT
96. CHECK FOR FUEL LEAKS
97. CHECK FOR ENGINE COOLANT LEAKS
98. CHECK FOR ENGINE OIL LEAKS
99. CHECK FOR EXHAUST GAS LEAKS
100. CHECK FOR LEAKAGE OF REFRIGERANT
101. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
102. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
103. ADJUST SHIFT LEVER POSITION
104. CHECK SHIFT LEVER POSITION
105. CHECK AND ADJUST FRONT WHEEL ALIGNMENT
106. CHECK IGNITION TIMING
107. CHECK ENGINE IDLE SPEED
108. CHECK CO/HC
109. CHECK ENGINE OIL LEVEL
110. CHECK FRONT DIFFERENTIAL OIL LEVEL (for 4WD)

111. INSTALL ENGINE UNDER COVER REAR LH (for 2WD)
a. Install the engine under cover rear LH with the bolt.
112. INSTALL ENGINE UNDER COVER REAR RH (for 2WD)

HINT: Install the RH side following the same procedures as for the LH side.

113. INSTALL NO. 2 ENGINE UNDER COVER (for 2WD)
114. INSTALL ENGINE UNDER COVER

115. INSTALL V-BANK COVER SUB-ASSEMBLY
a. Engage the 2 clips on the front of the cover, and then engage the clip on the rear to install the V-bank 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.

116. INSTALL ENGINE ROOM SIDE COVER LH
a. Install the side cover with the 5 clips.

117. INSTALL ENGINE ROOM SIDE COVER RH
a. Install the side cover with the 2 clips.

118. INSTALL COOL AIR INTAKE DUCT SEAL
a. Install the intake duct seal with the 11 clips.
119. PERFORM INITIALIZATION Testing and Inspection

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