Engine/Transmission, Installing
Engine/transmission, installing
Special tools:
951 2050 Bevel Protractor 951 2050 Bevel Protractor
951 2957 Coolant Reservoir 951 2957 Coolant Reservoir
951 2953 Cover 951 2953 Cover
Note! The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.
Installation
Note! For tightening torques, see Specifications, B8444S Tightening Torque.
Raising the engine/transmission unit
Caution! Ensure that no hoses, wiring or other components catch or become trapped during lifting.
Note! Make sure that the contact faces on the ball joints and link arms are clean.
Raise the engine/transmission unit using a lifting table. Stop approx. 15 cm before the sub-frame reaches the frame members.
Installing the A/C compressor
Install:
- the lower radiator hose in the mount on the sub-frame
- the A/C compressor; tighten 3 screws
Attach the connectors to:
- the A/C compressor
- the oil pressure sensor
- the oil level sensor; secure the cable harness in the clips and clamps.
Install the drive shaft in the hub on both sides.
Continue raising the engine to approx. 50 mm before it makes contact.
Caution! Guide the lower steering shaft into the hole in the firewall.
Guide the ball joint to the link arm.
Installing the sub-frame
Raise the sub-frame toward the frame members until it makes contact.
Install the sub-frame's four screws together with the sub-frame's brackets and engine heater, if installed.
Use new screws. Lube the screws with oil.
Tighten acc. to: Tightening torque, B8444S Tightening Torque. First tighten the screws on the sub-frame's left side, then on the right.
Use: 951 2050 BEVEL PROTRACTOR 951 2050 Bevel Protractor.
Tighten the screws for the brackets M10.
Remove the lifting table.
Installing components in the front assembly
Tighten the ball joint and link arm. See Tightening torque, B8444S Tightening Torque.
Counterhold with Torx 40 so that the ball joint gaiter does not rotate.
Install:
- the anti-roll bar links. Use new lock nuts. Tighten as specified: Tightening torque, B8444S Tightening Torque.
- new center screws and a rubber sleeve on the drive shafts. Tighten as specified: Tightening torque, B8444S Tightening Torque.
Installing track rods
Install the track rods following the marks made during removal. Use new lock nuts. Tighten as specified: Tightening torque, B8444S Tightening Torque.
Installing fuel lines
Note! Remove the seals.
Connect the fuel lines.
Attaching the steering gear connector
Attach the connector to the steering gear.
Installing the propeller shaft
Install the anti-roll bar. See: Propeller shaft, replacing, TF-80SC AWD Propeller Shaft.
Installing exhaust and intermediate pipes
Install:
- the intermediate pipes using new gaskets
- the nuts at intermediate pipe joints.
Installing components on the transmission
Install:
- the gear selector cable in the mount on the transmission and press the cable into the ball
- the transmission control module (TCM) connector.
Installing the radiator hoses
Install:
- the upper radiator hose on the distributor housing; tighten the clamp
- the lower radiator hose on the thermostat housing; tighten the clamp.
Connect the radiator hoses at the firewall.
Installing the oil cooler hoses
Remove the seals.
Install:
- the lower line to the transmission oil cooler as marked; secure with a quick-acting lock
- the upper line to the transmission oil cooler as marked; secure with a quick-acting lock.
Installing components
Install:
- the positive lead (1) in the electrical distribution box
- the ground cable (2) in the body (between the engine and body)
- the connector at the electrical distribution box (3)
- the connector to the brake vacuum valve and the vacuum hose on the valve leading to the brake vacuum amplifier.
Installing the air cleaner (ACL)
Install:
- the air cleaner; tighten the hose clip on the mass air flow sensor
- the brake vacuum hose on the brake pump
- the fresh air hose
- the 2 screws of the fresh air hose in the front plate
- the 2 connectors to the engine control module (ECM)
- the connector to the mass air flow sensor
- the band clamp on the cable harness in the air cleaner housing
- the cover over the air cleaner.
Installing the auxiliaries belt
Install the accessory drive belt. See Auxiliaries belt/belt tensioner, replacement, B8444S Service and Repair.
Installing the ground cable
Install:
- the ground cable between the engine and body, located beneath the expansion tank
- the screw; tighten.
Installing the servo oil reservoir
Install:
- the servo oil reservoir
- the return line for servo oil in the clips and clamps
- the screw on the washer fluid filler pipe; tighten
- the 3 ground cables in the body at the expansion tank
- the 3 screws; tighten
- the 2 coolant hoses to the expansion tank; tighten the clamps
- the connector to the electric cooling fan.
Installing the cover over the servo pump
Install:
- the cover over the servo pump
- the 2 screws; tighten
Installing the upper engine covers
Position the upper engine covers and press them into the retainers.
Installing the upper cross stay
Install:
- the upper cross stay between the suspension turrets
- the 4 screws in the suspension turrets; tighten
- the screw of the cross stay mount on the upper engine mount; tighten.
Installing the lower engine cover
Install:
- the lower engine cover
- the 6 screws; tighten.
Installing the protective plate
Install:
- the protective plate
- the 6 screws; tighten.
Installing wheels
Install the front wheels. See: Installing wheels Service and Repair.
Installing the battery cable
Fit the battery's negative cable in accordance with: Battery, disconnecting Battery Disconnecting.
Check
Caution! Make sure the outlet hose of filling equipment is not blocked as this could damage the cooling system.
Fill with coolant using filling equipment: 951 2957 Coolant Reservoir 951 2957 Coolant Reservoir and cover: 951 2953 Cover 951 2953 Cover.
Check the oil level in the engine and transmission. Start the engine and allow it to warm to normal operating temperature. Check for leaks and proper function. Fill up fluids as necessary.