Installation

WARNING:
- Do not re-use any fasteners that are worn or deformed in normal use.
- Some fasteners are designed to be used only once, and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts, washers, circlips and cotter pins. Always follow the recommendations - replace these fasteners with new parts where indicated, and any other time it is deemed necessary by inspection.

- Install engine in reverse order of removal, however observe following:
- Make sure dowel sleeves for centering engine to transmission are correctly installed in cylinder block.

Vehicles with manual transmission
- Lightly grease splines on transmission input shaft with G 000 100. Do not grease guide sleeve for release bearing.
- Make sure clutch disc is properly centered.
- Make sure pilot needle bearing is installed in flywheel.

Vehicles with automatic transmission

CAUTION: DO NOT install a pilot needle bearing.

- To mount torque converter to drive plate, only use bolts specified in parts catalog microfiche.
- Before installing engine, align torque converter and drive plate so that one hole in torque converter and one hole in drive plate are level with opening for starter.
- Check ATF level.

Checking installation position of torque converter





If the torque converter is installed correctly, the distance between contact surfaces at the mounting holes on the torque converter and contact surface of the bell housing flange (transmission 01V) will be approximately 23 mm (7/8 inch).
If the torque converter was not completely installed, this distance will be approximately 11 mm (7/16 inch).

CAUTION: If the torque converter is not installed correctly, the torque converter, drive plate or the ATF pump will be seriously damaged when the transmission is attached to the engine.

All models
- Install ribbed belt.
- Fill cooling system with engine coolant.

CAUTION:
- Only re-use engine coolant if you use the original cylinder head and cylinder block again.
- Do not re-use dirty coolant.

- Install engine mounts without tension or pre-load. Align engine by shaking engine before tightening engine mounts.
- Install lock carrier with attachments.
- Adjust accelerator pedal cable.
- Align exhaust system to relieve stress.
- Connect vacuum lines.
- Install spark plugs (if necessary) using 3122B spark plug removal tool.
For harness connections and routing:
Refer to Powertrain Management.
- After connecting battery, enter anti-theft code for radio.
- Fully close power windows in front doors.
- Operate all power window switches again for at least one second in "close" direction to activate "one-touch" opening/closing function.
- Set clock to correct time.
- Check oil level before starting engine.