ENGINE, INSTALLING
Tightening Specifications
Note. The tightening specifications apply only to lightly greased, oiled, phosphated or blackened nuts and bolts. Additional lubricants, such as engine or transmission oil are permissible, although lubricants containing graphite are not. Do not use any ungreased parts. Tightening specification tolerance +/- 15 %.
| Component | Nm | ||
|---|---|---|---|
| Bolts and nuts | M6 | 9 | |
| M7 | 15 | ||
| M8 | 20 | ||
| M10 | 40 | ||
| M12 | 65 | ||
Subframe mount, refer to SUBFRAME ASSEMBLY OVERVIEW .
Tighten the nut -2- to 15 Nm.
Engine to Transmission
| Item | Bolt 1) | Nm |
|---|---|---|
| 1 | M10 x 95 | 15 +90° |
| 2 ••• 5 | M12x75 | 30 +90° |
| 6, 7 | M12x140 | 30 +90° |
| 8, 9, 10 | M10x60 | 15 +90° |
| 11 | M10x45 | 15 +90° |
| A | Alignment sleeves for centering | |
| 1) Aluminum bolts may be used two times ENGINE, INSTALLING => The aluminum bolts -1 through 11- may be used two times. Therefore, the bolts must be marked with two notches "X" made by a chisel after they have been used the first time -arrow-. . | ||
| (1) To prevent damaging the bolts when marking them, do not clamp them in a vise. Insert the bolt using a 14 mm socket with a / 2 drive, which is inserted in to the vise, as illustrated. | ||
| (1) | To prevent damaging the bolts when marking them, do not clamp them in a vise. Insert the bolt using a 14 mm socket with a / 2 drive, which is inserted in to the vise, as illustrated. |
Scheme 120
- The aluminum bolts -1 through 11- may be used two times. Therefore, the bolts must be marked with two notches "X" made by a chisel after they have been used the first time -arrow-.
- Bolts marked with an "X" may not be used again.
Procedure
Note. Replace bolts that are tightened to the specification. Replace self-locking nuts and bolts and seals, gaskets and O-rings. Only remove the plugs or caps after installing the lines. The hose connections as well as the air guide pipes and hoses must be free of oil and grease before installing. To mount the air guide hoses on their connectors securely, spray the bolts on the used clamps with rust remover before installing. When installing, bring all cable ties back to same positions.
Install the left and right engine supports. Refer to SUBFRAME ASSEMBLY OVERVIEW .
Make sure the alignment sleeves -A- for centering the engine and transmission are inside the cylinder block and inside the timing chain guard lower section. Replace them if they are missing.
Scheme 121
| CAUTION | Installing the torque converter incorrectly can cause damage to the ATF pump drive plate. Checking position of torque converter. |
- When torque converter is installed correctly, distance -a- between the lower contact surface of threaded holes at torque converter and contact surface of bell housing is at least 23 mm.
Note. If torque converter is not completely inserted, distance is approximately 11 mm.
Before guiding engine and transmission together, rotate torque converter and drive plate so that the holes for the bolts are same height as opening for removed starter -1-.
| CAUTION | Risk of destroying automatic transmission. Keep checking whether the torque converter behind the drive plate can be turned before and during tightening of the bolts at engine/transmission connection. If the torque converter cannot be turned, it must be assumed that it is inserted incorrectly. Only secure torque converter to drive plate with new original bolts. |
Install the generator. Refer to GENERATOR .
Tighten the transmission to the engine.
Tighten the torque converter. Refer to FASTENER TIGHTENING SPECIFICATIONS .
The rest of the installation is performed in reverse order of removal, noting the following.
Install the starter. Refer to STARTER .
Attach the right coolant pipe to the transmission. Refer to RIGHT COOLANT PIPE ON TRANSMISSION .
Install the left rear coolant pipes to the transmission. Refer to LEFT REAR COOLANT PIPES ON TRANSMISSION .
Install ATF lines. Refer to ATF PIPES AND ATF COOLER .
Attach the front driveshaft to the transfer case. Refer to FRONT DRIVESHAFT .
Raise the engine/transmission assembly using the VAS 6131 A.
Install Air Conditioning (A/C) compressor. Refer to [For engine(s) CJWC, CJWB] Removal and Installation .
Align subframe, engine carrier and transmission carrier using marks made on longitudinal during removal.
Tighten bolts for the subframe, engine carrier and transmission carrier only to specified torque. Refer to FASTENER TIGHTENING SPECIFICATIONS . Do not tighten further (tighten bolts only after axle alignment).
| WARNING | Risk of accident due to loose connections. If the bolts in the subframe are not tightened to final torque, vehicle must not be driven. |
Install the universal joint on the steering gear. Refer to Removal and Installation .
Install the selector lever cable and adjust if necessary. Refer to SELECTOR LEVER CABLE .
Install the catalytic converter. Refer to LEFT CATALYTIC CONVERTER , RIGHT CATALYTIC CONVERTER .
Install exhaust system free of stress. Refer to EXHAUST SYSTEM, INSTALLING .
Attach the rear driveshaft to the transfer case. Refer to REAR DRIVESHAFT .
Install stabilizer bar. Refer to Removal and Installation .
Install brake caliper. Refer to Removal and Installation .
Install the suspension struts and control arms. Refer to Removal and Installation .
Install the Engine Control Module (ECM). Refer to Removal and Installation .
Install the cover for the plenum chamber E-box. Refer to [For engine(s) CJWC, CJWB] Removal and Installation .
Attach the electric wire to the battery jump start terminal -U6-. Refer to BATTERY JUMP START TERMINAL -U6 .
Attach the ground connection to the right longitudinal member. see scheme 76
Electrical connectors and wiring routing. Refer to appropriate SYSTEM WIRING DIAGRAM.
Follow all steps after connecting the battery. Refer to BATTERY, DISCONNECTING AND CONNECTING .
| CAUTION | There is a risk of destroying control modules with excess voltage. Do not use a charger as a starting aid. |
Install the hydraulic pipe. Refer to Description and Operation .
Install and adjust the windshield wiper arms. Refer to WINDSHIELD WIPER SYSTEM .
Fill engine oil and check oil level. Refer to the Maintenance Procedures Rep. Gr. 03.
Before starting engine for the first time, check the fluid level in power steering reservoir. Refer to Description and Operation .
Note. The power steering pump must not run dry.
Connect the coolant hoses with the connector coupling. (Scheme 122)
Scheme 122
Fill the coolant system COOLANT, DRAINING AND FILLING .
Note. Only reuse drained coolant if cylinder head or engine block was not replaced. Dirty coolant may not be used again.
Align subframe and engine carrier. Refer to Removal and Installation .
Align and tighten the transmission carrier. Refer to TRANSMISSION, INSTALLING .
Install the front wheel housing liners. Refer to Removal and Installation .
Perform axle alignment. Refer to WHEEL ALIGNMENT .
| WARNING | Risk of accident due to loose connections. Tighten subframe bolts to final torque after axle alignment. |
Install the noise insulation bracket and the noise insulation. Refer to Removal and Installation .
On vehicles with air suspension, deactivate vehicle lift mode. Refer to General Information .