Engine Installation

Engine Installation





1. Install the accessory brackets and tighten their bolts and nuts to the specified torques.
2. Push 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 upper bracket (A), then tighten the bolt and nuts in the numbered sequence shown.
4. Install the stop (B).








5. Install the transmission mount bracket. Tighten the bolt and nuts in the numbered sequence shown.
6. Remove the chain hoist from the engine.
7. Raise the hoist to full height.





8. Install the front beam. Align the marks on the rear beam (B) and front beam (C) then tighten the bolts.





9. Tighten the flange bolts on the radius rods.











10. Install the rear mount bracket, then tighten the bolts.
11. Lower the hoist.








12. Tighten the rear mount mounting bolt/nut (A).
13. Install the rear stiffener (B) (except '01-02 models A/T).





14. Tighten the front mount bracket mounting bolts in the numbered sequence shown.
15. Raise the hoist to full height.
16. 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.
17. Connect the suspension lower arm ball joints. Use new cotter pins.
18. Install the damper fork.





19. Install the A/C compressor.





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





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





24. Connect the upper radiator hose (A), lower radiator hose (B) and heater hoses (C).





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





26. Install the splash shield.
27. Install the front tires/wheels.
28. Lower the hoist.





29. Install the clutch slave cylinder and line/hose assembly take care not to bend the line (M/T).





30. Install the shift cable (A) and select cable (B); use new cotter pins (C).
31. Loosely install the alternator belt.
32. Loosely install the P/S pump belt and pump.
33. Adjust the alternator belt and the Power Steering (P/S) pump belt.





34. Install the starter cable (A), wire harness clamp (B), ground cable (C) and back-up light switch connectors (D).





35. Connect the engine wire harness connectors on the right side of the engine compartment.





36. Push the ECM/PCM connectors through the bulkhead, then install the grommet (A).





37. Connect the ECM/PCM connectors.





38. Install the brake booster vacuum hose (A), Evaporative Emission (EVAP) canister hose (B) and vacuum hoses (C).





39. Install the fuel feed hose (A) and fuel return hose (B). using new washers (C).
40. Install the cruise control cable, then adjust the cable.
41. Install the throttle cable, then adjust the cable.





42. Install the under-hood fuse/relay box (A), then connect the connector (B) and battery cable (C) on the under-hood fuse/relay box.





43. Install the intake air duct.
44. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion.
45. Refill the engine with engine oil.
46. Refill the transmission with MTF or ATF.
47. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
48. Move the shift lever to each gear, and verify that the A/T gear position indicator follows the transmission range switch (A/T).
49. Check that the transmission shifts into gear smoothly (M/T).
50. 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 line.
51. Enter the anti-theft code for the radio, then enter the customer's radio station presets.