Installation

INSTALLATION





IMPORTANT: Be sure the frame alignment tool fully engages in all gauge holes.

1. Install new cage nuts into the body as torque retention of old nuts may not be sufficient.
2. Raise frame assembly to body.

IMPORTANT: Do not tighten fastener at this time.





3. Install new frame-to-body bolts.





4. Install new cage nuts into the body for the suspension supports, as torque retention of old nuts may not be sufficient.
5. Install suspension supports using new bolts and tighten all frame bolts using Torque Angle Gauge SA9140E (or equivalent).
Torque: Suspension Support-to-Body Bolts: 90 Nm (66 ft. lbs.) +45° to 60°





6. Install lower control arm ball stud into steering knuckle. Hold the bolt stationary while turning the nut.
Torque: Lower Control Arm-to-Steering Knuckle: 100 Nm (75 ft. lbs.)





7. On vehicles equipped with L61 and manual transaxle, install cradle to shifter link pivot pin clip.





8. Install steering gear-to-frame using new bolts and nuts and tighten using Torque Angle Gauge SA9140E (or equivalent).
Torque: Steering Gear-to-Frame: 45 Nm (35 ft. lbs.) + 90°
9. Vehicles equipped with an L61 engine and automatic transaxle, install steering gear heat shield.
Torque: Steering Gear Heat Shield-to-Frame: 4 Nm (35 inch lbs.)

NOTICE: Hold ball stud from turning when tightening nut. The rubber boot can become torn and damaged if the ball stud turns.





10. Using new nuts, install stabilizer bar link-to-strut assembly.
Torque: Stabilizer Bar Link-to-Strut: 65 Nm (48 ft. lbs.)
11. Inspect rubber boots for damage and replace if damaged.





12. Install rear transaxle mount.
13. Install two rear transaxle mount to frame bolts.
Torque: Rear Transaxle Mount-to-Frame Bolts: 60 Nm (44 ft. lbs.)





14. Install front transaxle mount through bolt.
Torque: Front Transaxle Mount Through Bolt: 55 Nm (41 ft. lbs.)





15. Install exhaust manifold pipe on L81 engines and on L61 engines with manual transaxles. (L81 shown)
16. Tighten exhaust manifold pipe to exhaust manifold.
Torque: Exhaust Manifold Pipe-to-Exhaust Manifold Nuts: 30 Nm (22 ft. lbs.)
17. Tighten exhaust manifold pipe to exhaust pipe.
Torque: Exhaust Manifold Pipe-to-Pipe Bolts: 20 Nm (15 ft. lbs.)





18. On L61, install O2 sensor clamp to underbody attachment nut.
Torque: O2 Sensor Clip-to-Underbody Attachment Nut: 4 Nm (35 inch lbs.)





19. Reattach A/C line clip to front of frame assembly.





20. Install right front lower splash shield.
Torque: Right Splash Shield-to-Body: 5 Nm (44 inch lbs.)
21. Install left front wheel liner push pin to frame.

NOTICE: Before installing wheels, remove rust or corrosion from wheel mounting surfaces and brake rotors. Failure to do so can cause wheel bolts to loosen in service.





22. Connect O2 sensor electrical connector and reattach harness to frame.
23. Position wheel onto hub.
24. Install wheel bolts and tighten in a star pattern.
24.1. Hand tighten all five wheel bolts.
24.2. Use a torque wrench to tighten wheel bolts using a star pattern.
Torque: Wheel Bolts (Initial Torque): 63 Nm (46 ft. lbs.)
24.3. Use a torque wrench to final tighten wheel bolts using a star pattern.
Torque: Wheel Bolts (Final Torque): 125 Nm (92 ft. lbs.)
25. Lower vehicle from hoist.





26. Install remaining rear transaxle mount to frame bolt.
Torque: Rear Transaxle Mount-to-Frame Bolts: 60 Nm (44 ft. lbs.)
27. Install rear transaxle mount through bolt and heat shield (on vehicle with 4-cylinders automatic).
Torque: Rear Transaxle Mount Through Bolt: 90 Nm (66 ft. lbs.)





28. On vehicles equipped with L81 engines, install exhaust manifold pipe heat shield.
Torque: Exhaust Manifold Pipe Heat Shield Bolts (L81): 8 Nm (71 inch lbs.)
29. Perform vehicle alignment.