Engine Installation
  1. Install the accessory brackets and tighten their bolts to the specified torques.
  1. Position the engine/transmission assembly under the vehicle. Be sure that they are properly aligned. Carefully lower the vehicle until the engine and transmission are properly positioned in the engine compartment. Make sure the vehicle is not resting on any part of the engine or transmission. Attach the chain hoist using the sling belt and karabiner to the engine/transmission as shown.
    NOTE: Reinstall the mounting bolts/support nuts in the sequence given in the following steps. Failure to follow this sequence may cause excessive noise and vibration, and reduce engine mount life.
  1. Carefully raise the engine/transmission assembly into place.
  1. Loosen the upper torque rod mounting bolt (A).
  1. Tighten the new side engine mount bracket mounting bolt and nuts (A).
  1. Install the ground cable (B).
  1. Tighten the new transmission mounting bolt and nuts (A).
  1. Install the ground cable (B).
  1. Make sure the hoist bracket are positioned properly. Raise the hoist to full height.
  1. Support the front subframe with the wood piece and a jack, and install the new subframe.
  1. Install the lower torque rod, then tighten the new lower torque rod mounting bolts in the numbered sequence shown.
  1. Make sure the hoist brackets are positioned properly. Lower the vehicle on the hoist.
  1. Disconnect the chain hoist from the engine/ transmission assembly.
  1. Tighten the upper torque rod mounting bolt.
  1. Raise the vehicle on the hoist to full height.
  1. Install the intercooler intake pipe (A) to the turbocharger outlet hose (B), then install the intercooler intake pipe bracket (C).
  1. Loosely tighten the intercooler intake pipe mounting bolts (D). Align the mark (E) on the intercooler intake pipe and the mark (F) on the turbocharger outlet hose, and slide the turbocharger outlet hose over the intercooler intake pipe until the hose end contact the bulge (G).
  1. Tighten the intercooler intake pipe mounting bolts, and secure the turbocharger outlet hose with the band (H), then install the intercooler intake hose (I), and secure the hose with band (J).
  1. Connect the connectors to the steering gearbox.
  1. Install a new set ring on the end of each driveshaft, then install the driveshafts. Make sure each ring ‘‘clicks'' into place in the differential and intermediate shaft.
  1. Install the diesel particulate filter (DPF) (A). Use new gaskets (B) and new self locking nuts (C). Connect the exhaust gas temperature (EGT) sensor 2 connector (D), and install the DPF differential pressure hoses (E) (with DPF).
  1. Install the catalytic converter/exhaust pipe A assembly (A). Use new gaskets (B) and new self locking nuts (C) (without DPF).
  1. Lower the vehicle on the hoist.
  1. Install the heater hoses.
  1. Install the A/C compressor.
  1. Install the A/C line (A) on the clamp (B).
  1. Install the water bypass hose (C).
  1. Align the reference mark (A) on the steering joint and steering gearbox pinion shaft. Connect the steering joint (B) to the steering gearbox pinion shaft (C). Tighten the steering joint bolt.
  1. Install the steering joint cover (D).
  1. Install the fuel return hose (A) and brake booster vacuum hose (B).
  1. Install the fuel hose.
  1. Install the shift cable bracket.
  1. Install the intercooler outlet hose.
  1. Install the battery cables (A) to the under-hood fuse/relay box.
  1. Connect the engine wire harness connectors (B).
  1. Install the bracket (A), then install the air cleaner housing bracket (B) and the harness clamp (C).
  1. Install the battery base bracket (A), then install the battery base (B).
  1. Remove the harness clamp (C).
  1. Install the two bolts (A) securing the clutch line bracket, then install the harness clamp (B).
  1. Install the air flow tube.
  1. Install the engine cover.
  1. Install the battery.
  1. Install the engine undercover.
  1. Install the front wheels.
  1. Install the battery. Clean the battery posts and cable terminals with sandpaper, then assemble them, and apply grease to prevent corrosion.
  1. Check that the transmission shifts into gear smoothly.
  1. Set the clock.