Engine Installation

Engine Installation





1. Install the accessory brackets. Tighten their bolts and nuts to the specified torques.
2. Position the engine under the vehicle. Attach the chain hoist to the engine, then lift the engine into position in the vehicle.

NOTICE: Reinstall the mounting bolts/nuts in the sequence given. Failure to follow this sequence may cause excessive noise and vibration, and reduce bushing life.





3. Install the transmission lower rear mount.








4. Install the rear mount bracket.





5. Install the A/C compressor.





6. Install the front beam. Align mark (A) on the rear beam (B) and front beam (C), then tighten the bolts.
7. Tighten the transmission lower rear mount mounting nuts (D) and transmission lower front mount mounting nuts (E).





8. Tighten the flange bolts on the radius rods.
9. Lower the hoist.





10. Tighten the front mount bracket support nut.








11. Tighten the rear mount bracket support nut (A) and mounting bolt (B).





12. Install the side engine mount bracket, then tighten the mounting bolts in the numbered sequence shown.
13. Remove the chain hoist from the engine.
14. Raise the hoist to full height.
15. Install a new spring clip on the end of each driveshaft, then install the driveshafts. Make sure each clip "clicks" into place in the differential and intermediate shaft.
16. Connect the suspension lower arm ball joints. Use new cotter pins.
17. Install the damper fork.





18. Install exhaust pipe A (A); use new gaskets (B) and new self locking nuts (C).





19. Install the control lever (A) with the shift cable, on the control shaft. Do not bend the shift cable any more than is necessary to install the control lever.
20. Install the lock bolt (B) with a new lock washer (C), then bend the lock tab of the lock washer.
21. Install the shift cable cover (D), then install the shift cable holder (E) on the shift cable cover.





22. Install the Power Steering (P/S) hose on the clamps (A), and connect the engine mount control vacuum hose (B).





23. Install the splash shield.
24. Install the front tires/wheels.
25. Lower the hoist.





26. Install the P/S hose clamp.





27. Install the upper radiator hose (A) and lower radiator hose (B).








28. Install the heater hoses.





29. Install the Automatic Transmission Fluid (ATF) cooler hoses (A) ('99 model).
30. Install the ground cable (B) (J32A1 engine).
31. Install the alternator belt.
32. Loosely install the P/S pump belt and pump.
33. Adjust the P/S pump belt.





34. Install the power steering speed sensor (A) with a new O-ring (B).
35. Connect the Vehicle Speed Sensor (VSS) connector (C) ('99 model).





36. Push the Powertrain Control Module (PCM) connectors through the bulkhead. Install the grommet, and tighten the mounting nuts (A).





37. Connect the PCM connector (A), and install the harness clamps (B).





38. Install the under-hood fuse relay box (A), and tighten the flange bolt (B).
39. Install the battery cables (C) on the under-hood fuse relay box. Install the harness clamps (D). Install the battery cable grommet (E).





40. Install the engine wire harness clamps.





41. Install the vacuum hoses (A), then connect the Primary Heated Oxygen Sensor (primary H02S) connector (B).








42. Install the brake booster vacuum hose (A) and vacuum hose (B).








43. Install the fuel feed hose (A) and fuel return hose (B) with new washers (C).





44. Install the starter cable (A).
45. Install the ground cable (B) ('02-03 models).





46. Install the ground cable (A) and harness clamp (B) (J32A2 engine).
47. Connect the engine wire harness connectors (C), and install the harness clamp (D) on the left side of the engine compartment.





48. Install the battery base bracket (A), then install the battery base (B) and harness clamp (C).








49. Install the intake air duct (A), then install the vacuum hose (B) and breather pipe (C).
50. Install the Evaporative Emission (EVAP) canister hose (D).
51. Install and adjust the cruise control cable.
52. Install and adjust the throttle cable.





53. Tighten the bolt (A) securing the TCS control valve bracket. Connect the TCS control valve angle sensor connector (B), TCS control valve actuator connector (C) and water bypass hoses (D) on the TCS control valve assembly (J32A2 engine).





54. Install the intake manifold cover ('00-03 models).
55. Install the battery. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion.
56. Refill the engine with engine oil.
57. Refill the Automatic Transmission Fluid (ATF):
^ '99 model.
^ '00-03 models.
58. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
59. Move the shift lever to each gear, and verify that the A/T gear position indicator follows the transmission range switch.
60. Inspect for fuel leaks. Turn the ignition switch ON (II) (do not operate the starter) so the fuel pump runs for about 2 seconds and pressurizes the fuel line. Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
61. Perform the PCM idle learn procedure.
62. Perform the power window control unit reset procedure ('02-03 models).
63. Inspect the idle speed.
64. Inspect the ignition timing.
65. Enter the anti-theft code for the radio, then enter the customer's radio station presets.