Installation

INSTALLATION
1. INSTALL DRIVE PLATE

HINT: The mounting bolts are tightened in 2 progressive steps (steps (c) and (e)).

If any one of the mounting bolts is broken or deformed, replace it.





a. Apply adhesive to 2 or 3 threads of the mounting bolt end.

Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent





b. Install the front spacer, drive plate and rear spacer on the crankshaft.
c. Install and uniformly tighten the 8 mounting bolts in several passes, in the sequence shown.

Torque: 49 Nm (36 ft. lbs.)

If any one of the mounting bolts does not meet the torque specification, replace the mounting bolt.





d. Mark the mounting bolt with paint.
e. Retighten the mounting bolts by 90� in the numerical order shown.
f. Check that the painted mark is now at a 90� angle to (e).





2. INSTALL TRANSMISSION TO ENGINE
a. Check the torque converter clutch installation.
b. Attach the transmission to the engine.
c. Install the ground strap and 10 bolts.

Torque:
37 Nm (27 ft. lbs.) for 14 mm head
72 Nm (53 ft. lbs.) for 17 mm head





3. INSTALL TORQUE CONVERTER CLUTCH BOLTS
a. Apply adhesive to 2 or 3 threads of the bolt end.

Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent





b. Hold the crankshaft pulley bolt with a wrench, and install the 6 bolts evenly.

Torque: 48 Nm (35 ft. lbs.)

HINT: First install the black colored bolt, install the other bolts.





c. Install the flywheel housing under cover with the 2 bolts.

Torque: 18 Nm (13 ft. lbs.)

4. INSTALL OIL COOLER PIPE FOR TRANSMISSION
5. INSTALL OIL DIPSTICK GUIDE AND DIPSTICK FOR TRANSMISSION
a. Install a new O-ring to the dipstick guide.
b. Apply soapy water to the O-ring.
c. Connect the dipstick guide end to the dipstick tube of the oil pan.
d. Install the dipstick guide with the bolt.
e. Install the dipstick.
f. Connect the 2 breather hoses to the dipstick guide.
6. CONNECT ENGINE WIRE TO TRANSMISSION
a. Connect the 5 connectors.
b. Connect the 2 wire clamps.





7. INSTALL ENGINE AND TRANSMISSION ASSEMBLY IN VEHICLE
a. Attach the engine chain hoist to the engine hangers.
b. Slowly lower the engine and transmission assembly into the engine compartment.
c. Attach the engine mounting brackets to the frame brackets.





d. Keep the engine level with a jack.





e. Install the frame crossmember with the 8 bolts and 4 nuts.

Torque:
50 Nm (37 ft. lbs.) for bolts
74 Nm (55 ft. lbs.) for nuts

f. Install the transfer case protector with the 3 bolts.





g. Install the 2 nuts and 4 bolts holding the engine mounting brackets to the frame brackets.

Torque: 30 Nm (22 ft. lbs.)

h. Remove the engine chain hoist.
8. INSTALL PS PUMP
Install the PS pump with the 3 bolts.

Torque: 17 Nm (13 ft. lbs.)





9. INSTALL A/C COMPRESSOR
Install the A/C compressor with the 3 bolts.

Torque: 49 Nm (36 ft. lbs.)

b. Connect the A/C compressor connector.
10. INSTALL STABILIZER BAR
11. INSTALL PROPELLER SHAFT
12. INSTALL FRONT EXHAUST PIPES





13. INSTALL SHIFT LEVER ASSEMBLY AND TRANSFER SHIFT LEVER ASSEMBLY
a. Install the transfer shift lever.
1) Install a new gasket and the shift lever with the 4 bolts.
2) Connect the transfer shift lever rod to the shift lever with the bushing, wave washer, plate washer and clip.
b. Install the transfer shift lever boot with the 4 bolts.





c. Install the shift lever assembly.
1) Connect the transmission control rod to the shift lever assembly with the plate washer and clip.
2) Install the shift lever assembly with the 6 bolts.
3) Connect the connector.
d. Install the console upper cover.
e. Install the transfer shift lever knob.
14. CONNECT HOSES, WIRES, CONNECTORS, CLAMPS,GROMMET AND CABLES
- Accelerator cable to engine
- 2 PS air hoses to hose clamp on No.3 RH timing belt cover
- Generator wire
- Generator connector
- Hose clamp for PS air hose
PS air hose to upper intake manifold
- 2 heater hoses
- Engine wire clamp to bracket on cowl panel
- Engine wire grommet to cowl panel
- Ground strap connector
- Fuel inlet hose and clamps
- Fuel return hose and clamp
- Air inlet hose to charcoal canister
- EVAP hose to charcoal canister
- Engine wire to clamp on right fender apron
- Clamp on battery negative (-) cable to relay box
- Battery negative (-) cable to right fender apron
- Battery positive (+) terminal cable
15. CONNECT ENGINE WIRE TO CABIN
a. Connect the 3 wire harness connectors.
b. Install the ECM with the 3 screws.
c. Connect the 3 connectors to the ECM.
d. Install these parts:
1) Glove compartment door
2) Lower No.2 panel
16. INSTALL FAN PULLEY, FAN, FLUID COUPLING AND GENERATOR DRIVE BELT
a. Temporarily install the fan pulley, the fan and fluid coupling assembly with the 4 nuts.
b. Install the generator drive belt.
c. Tighten the 4 nuts holding the fluid coupling to the fan bracket.
17. INSTALL RADIATOR AND FAN SHROUD
a. Place the fan shroud in the installation position.
b. Install the radiator with the 2 support collars, 2 nuts and 2 bolts.
c. Connect the 2 A/T oil cooler hoses to the radiator.
d. Install the lower radiator hose.
e. Attach the lower side of the fan shroud to the brackets of the radiator, and install the fan shroud with the 3 bolts.
Install the 2 brackets on the wire to the radiator with the 2 bolts.
Install the 2 clamps on the A/C discharge tube to the brackets on the wire with the 2 nuts.
h. Connect the upper radiator hose to the front water bypass joint.
18. INSTALL RADIATOR RESERVOIR
a. Install the grommet to the reservoir.
b. Attach the lower side of the reservoir to the fan shroud.
c. Install the reservoir with the 2 bolts.
d. Connect the reservoir hose to the radiator.
e. Install the clamp on the wire to the reservoir.
19. INSTALL AIR CLEANER CAP AND INTAKE AIR CONNECTOR PIPE ASSEMBLY
20. INSTALL BATTERY
21. FILL WITH ENGINE COOLANT
22. FILL WITH ENGINE OIL
23. START ENGINE AND CHECK FOR LEAKS
24. INSTALL V-bank COVER
25. INSTALL ENGINE UNDER COVERS
26. INSTALL HOOD
27. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
28. RECHECK ENGINE COOLANT AND OIL LEVELS