Engine Installation

Engine Installation





1. Install the accessory brackets and 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 (D).
7. Tighten the transmission lower rear mount mounting nuts (E) and transmission lower front mount mounting nuts (F).





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 and mounting bolt.





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). Then connect the Primary Heated Oxygen Sensor connector (D).





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 P/S hose into the clamps (A), and connect the engine mount control vacuum hose (B).





23. Connect the upper radiator hose (A), and the lower radiator hose (B).





24. Install the heater hoses, then install the distributor cap.





25. Connect the Automatic Transmission Fluid (ATF) cooler hoses.





26. Install the splash shield.
27. Install the front tires/wheels.
28. Lower the hoist.
29. Install the alternator belt.
30. Loosely install the Power Steering (P/S) pump belt and pump.
31. Adjust the Power Steering (P/S) pump belt.





32. Push in the Powertrain Control Module (PCM) connectors, through the bulkhead then install the grommet (A).





33. Connect the PCM connectors.





34. Install the starter cable clamps.





35. Install the under-hood fuse/relay box (A) and harness clamps (B).
36. Install the battery cables (c), and connect the connector (D) from the under-hood fuse/relay box (A).





37. Install the engine wire harness clamps.





38. Install the brake booster vacuum hose (A) and the cruise control vacuum hose (B).








39. Install the fuel hose (A) and fuel return hose (B), using new washers (C).





40. Connect the engine wire harness connectors on the left side of the engine compartment.
41. Install the cruise control cable, then adjust the cable.
42. Install the throttle cable, then adjust the cable.





43. Install the battery base bracket (A), battery base (B), then install the ground cable (C) and harness clamp (D).





44. Install the throttle body cover (A) and intake manifold cover (B).





45. Install the intake air duct (A), then install the vacuum hose (B) and breather pipe (C).
46. Install the Evaporative Emission (EVAP) canister hose (D) to the throttle body.
47. Install the battery. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion.
48. Refill the engine with engine oil.
49. Refill the transmission with Automatic Transmission Fluid (ATF).
50. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
51. Move the shift lever to each gear, and verify that the A/T gear position indicator follows the transmission range switch.
52. Inspect for fuel leaks. Turn on (II) the ignition switch (do not operate the starter) so that the fuel pump runs for approximately 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 lines.
53. Enter the anti-theft code for the radio, then enter the customer's radio station presets.