Installation

INSTALLATION

1. M/T: INSTALL CLUTCH DISC AND COVER TO FLYWHEEL
2. CONNECT TRANSMISSION TO ENGINE
3. PLACE ENGINE WITH TRANSMISSION IN VEHICLE

a. Attach the engine hoist chain to the lifting brackets on the engine.
b. Lower the engine with transmission into the engine compartment.

4. 4WD: PLACE JACK UNDER TRANSMISSION

Be sure to put a wooden block between the jack and the transmission pan.

5. JACK UP AND PUT TRANSMISSION ONTO MEMBER
6. INSTALL ENGINE MOUNTING TO FRAME BRACKET

a. Align the engine mounting and frame bracket.
b. Install the engine mounting bolts on each side of the engine.
c. Remove the hoist chain.

7. 2WD: INSTALL ENGINE REAR MOUNTING AND BRACKET

a. Raise the transmission slightly by raising the engine with a jack and a wooden block under the transmission.






b. Install the engine rear mounting bracket to the support member. Torque the 2 bolts.

- Torque: 13 N.m (130 kgf.cm, 9 ft.Ibf)

c. Lower the transmission and rest it on the extension housing.
d. Install the bracket to the mounting. Torque the 4 bolts.

- Torque: 25 N.m (260 kgf.cm. 19 ft.Ibf)







4WD: INSTALL NO.2 FRAME CROSSMEMBER

a. Raise the transmission slightly with a jack.
b. Install the No.2 frame crossmember to the side frame with the 4 bolts. Torque the bolts.

- Torque: 95 N.m (970 kgf.cm. 70 ft.Ibf)

c. Lower the transmission and transfer.
d. Install the 4 mounting bolts to the engine rear mounting. Torque the bolts.

- Torque: 13 N.m (130 kgf.cm. 9 ft.Ibf)

8. 4WD: INSTALL BRAKE TUBE HEAT INSULATOR AND NO.1 FRONT FLOOR HEAT INSULATOR






9. M/T: INSTALL CLUTCH RELEASE CYLINDER WITH BRACKET TO TRANSMISSION

- Torque: 39 Nm (400 kgf.cm, 29 ft.Ibf) for Bracket
- Torque: 12 N.m (120 kgfcm, 9 ft.lbf) for Release cylinder






10. INSTALL EXHAUST PIPE

a. Connect the exhaust pipe to the catalytic converter.
b. Connect the exhaust pipe to the exhaust manifold.
c. Install the exhaust pipe clamp.
d. Connect the oxygen sensor connector.

11. INSTALL NO.1 FRAME CROSSMEMBER
12. 4WD: INSTALL FRONT PROPELLER SHAFT
13. 4WD: INSTALL STABILIZER BAR (See SA section)
14. 4WD: INSTALL TRANSFER UNDER COVER
15. CONNECT SPEEDOMETER CABLE







16. 4WD A/T: CONNECT TRANSFER SHIFT LINKAGE

a. Apply MP grease to the cross shaft joint.






b. Install the cross shaft to the body.






c. Connect the No.1 and No.2 transfer shift linkage to the cross shaft.

17. A/T: CONNECT MANUAL SHIFT LINKAGE TO PNP SWITCH
18. INSTALL PROPELLER SHAFT
19. R150: INSTALL SHIFT LEVER RETAINER






20. M/T: INSTALL SHIFT LEVER

a. Apply MP grease to the shift lever.
b. Install the shift lever to the transmission.

21. CONNECT GROUND STRAPS TO ENGINE REAR SIDE AND RH SIDE
22. WI A/C: INSTALL COMPRESSOR TO BRACKET

a. Install the compressor with the 4 bolts.
b. Install the drive belt and adjust the belt tension.

23. CONNECT GROUND STRAP FOR PS PUMP BRACKET







24. w/PS: INSTALL PS PUMP WITH PS PUMP BRACKET

Install the PS pump with the 4 bolts.

25. CONNECT FOLLOWING CABLES:

a. A/T:Throttle cable
b. W/Cruise control: Cruise control cable
c. Accelerator cable

26. CONNECT FOLLOWING HOSES:

a. Charcoal canister hose to canister
b. W/Cruise control: Cruise control vacuum hose
c. Brake booster hose
d. PS air hoses to gas filter and air pipe

27. CONNECT FOLLOWING WIRES AND CONNECTORS:

a. w/ A/C: A/C compressor connector
b. Check connector
c. M/T: Starter relay connectors
d. ECM connectors
e. Ground strap to engine rear side
f. Distributor wire
g. High-tension cords
h. Generator wires
i. Igniter connector
j. Generator connector and wire
k. Ground strap to LH fender apron

28. INSTALL FAN PULLEY, BELT GUIDE, FLUID COUPLING AND GENERATOR DRIVE BELT
29. W/ A/C: INSTALL A/C BELT

30. INSTALL PS PUMP AND BELT

a. Place the PS drive onto each pulley.
b. Stretch the belt tight and tighten the nuts.
c. Torque the PS pump pulley lock nut.

- Torque: 43 Nm (440 kgf.cm, 32 ft.lbf)

d. Adjust the belt tension

31. INSTALL RADIATOR
32. INSTALL AIR CLEANER CASE AND INTAKE AIR CONNECTOR
33. FILL WITH ENGINE OIL
34. FILL WITH COOLANT
35. INSTALL ENGINE UNDER COVER
36. INSTALL BATTERY
37. INSTALL HOOD
38. START ENGINE

Warm up the engine and inspect for leaks.

39. PERFORM ENGINE ADJUSTMENT
40. ROAD TEST

Road test the vehicle.

41. RECHECK COOLANT AND ENGINE OIL LEVEL