Installation

Engine Installation w/ Automatic Transmission

1. Clean engine and gearbox mating faces.
2. Clean dowel and dowel holes.
3. Position hoist above engine.
4. Connect lifting chains to engine.
5. Raise engine from work bench and position above engine compartment.
6. Position jack beneath gearbox fluid pan and raise transmission to ease alignment of bell housing to engine.

CAUTION: Use a block of wood or hard rubber pad to protect fluid pan.

7. With assistance, lower engine into engine compartment.

CAUTION: During the engine fitment procedure ensure that the engine does not damage any surrounding components.

8. With assistance, align engine to bell housing dowels.
9. Fit bolts securing bell housing to engine and tighten to 46 Nm (34 ft. lbs.).

NOTE: Align harness brackets to 2 uppermost bell housing retaining bolts.

10. Remove jack supporting gearbox fluid pan.
11. Lower engine hoist ensuring mountings are aligned with chassis brackets.
12. Disconnect lifting chains from engine eyes.
13. Remove lifting tool LRT-1 2-514 from hoist.
14. Remove hoist from above vehicle.
15. Position engine harness around engine.
16. Connect ignition coil multiplug and secure to bracket.
17. Connect LH injector multiplugs.
18. Connect gauge temperature thermistor.
19. Connect multiplug to fuel temperature sensor.
20. Connect multiplug to ECT sensor.
21. Connect RH bank high tension leads to spark plugs and secure to guides.
22. Connect RH rocker cover breather pipe to ram housing.
23. Connect RH injector multiplugs.
24. Align engine harness to RH side of inlet manifold and secure with screws.
25. Fit heater hose/pipe assembly to inlet manifold and secure with clip.
26. Align heater pipe to bracket and secure with screw.
27. Position alternator terminal leads and secure.
28. Route harness down front of engine.
29. Connect connector to the oil pressure switch
30. Connect multiplug to camshaft position sensor.
31. Connect radiator bottom hose to heater pipe and secure with clip.
32. Raise vehicle.
33. Fit nut securing LH engine mounting rubber to chassis mounting and tighten to 30 Nm (22 ft. lbs.).
34. Fit nut securing RH engine mounting rubber to chassis mounting and tighten to 30 Nm (22 ft. lbs.).
35. Fit bell housing to engine bolts and tighten to 46 Nm (34 ft. lbs.).
36. Remove piece of wood from bell housing access hole.
37. Align converter to drive plate.
38. Fit bolts securing converter to drive plate and tighten to 45 Nm (33 ft. lbs.).

NOTE: Rotate crankshaft during the above procedure.

39. Fit bell housing access plate and secure with bolts tightened to 9 Nm (7 ft. lbs.).
40. Clean bell housing cover plate and mating face.
41. Fit plate and secure with bolts tightened to 9 Nm (7 ft. lbs.).
42. Connect multiplug to crankshaft position sensor.
43. Fit crankshaft position sensor heat shield and secure with screw.
44. Position engine harness to LH engine mounting bracket and secure with cable tie.
45. Connect multiplug to LH knock sensor.
46. Position engine harness to RH engine mounting bracket and secure with cable ties.
47. Connect multiplug to RH knock sensor.
48. Connect connector to starter motor solenoid.
49. Position battery leads to starter motor solenoid terminal and secure with nut.
50. Position starter motor heat shield.
51. Clean exhaust manifold to front pipe mating faces.
52. Fit new front pipe to manifold gaskets.
53. Connect front pipe to manifold studs and secure with nuts.
54. Secure starter motor heat shield clip to solenoid.
55. Align starter motor heat shield to RH engine mounting bracket and secure with bolt.
56. Align RH catalyst heat shield to chassis and secure with bolt.
57. Lower vehicle.
58. Remove 3 bolts securing engine front lifting bracket, retain bracket but discard bolts.
59. Position engine lifting bracket to PAS pump, align to cylinder head and secure with bolts tightened to 35 Nm (25 ft. lbs.).
60. Secure knock sensor harness clip to PAS return hose.
61. Fit PAS pulley to pump, fit bolts but do not tighten.
62. Position brake servo pipe and connect to inlet manifold.
63. Position purge pipe and secure to coolant hose and harness with cable ties.
64. Fit intake hose to MAP sensor housing and secure with clip.
65. Position breather pipe 'P clip to RH cylinder head and secure with bolt.
66. Fit plenum.
67. Remove plugs from fuel return and feed hose connections.
68. Clean fuel feed pipe connections.
69. Connect feed hose to fuel rail and tighten union.
70. Connect fuel return hose to fuel rail and secure with clip.
71. Connect heater feed and return hoses to pipes and secure with clips.
72. Release A/C compressor and position to mounting bracket.
73. Position heat shield to compressor fixing, fit bolts and tighten to 25 Nm (18 ft. lbs.).
74. Connect compressor multiplug.
75. Clean drive belt and pulley grooves.
76. Using a 15 mm spanner, rotate tensioner clockwise, fit belt to pulleys and release tensioner.
77. Tighten PAS pump pulley bolts to 10 Nm, 7 ft. lbs.).
78. Fit radiator.
79. Fit bonnet.
80. Refill engine oil.
81. Adjust kick-down cable.