Installation

INSTALLATION





1. INSTALL TRANSMISSION TO ENGINE
2. INSTALL ENGINE AND TRANSMISSION ASSEMBLY IN VEHICLE
a. Attach the engine hoist chain to the engine hangers.
b. Lower the engine and transmission assembly into the engine compartment.





c. Keep the engine level, and align the RH and LH mountings and body mountings.
d. Attach the RH and LH mounting insulators to the body mountings, and temporarily install the 4 bolts and nuts.
e. Jack up and put the transmission onto the frame.
f. Remove the hoist chain.
g. Remove the bolt and rear engine hanger.





3. INSTALL ENGINE REAR MOUNTING BRACKET
a. Raise the transmission slightly by raising the engine with a jack and a wooden block under the transmission.
b. Install the engine rear mounting bracket to the frame.

Torque: 25 Nm (19 ft. lbs.)

c. Lower the transmission and rest it on the extension housing.
d. Install the mounting bracket to the mounting insulator.

Torque: 18 Nm (13 ft. lbs.)





4. TIGHTEN RH AND LH ENGINE MOUNTING INSULATOR BOLTS AND NUTS
Tighten the 4 bolts and nuts holding the mounting insulators to the body mountings.

Torque: 38 Nm (28 ft. lbs.)

5. CONNECT STARTER WIRE
a. Connect the ground strap with the bolt.
b. Connect the starter connector.
c. Connect the starter wire with the nut.
6. M/T: INSTALL CLUTCH RELEASE CYLINDER
a. Connect the clutch line with the bolt.

Torque: 39 Nm (29 ft. lbs.)





b. Install the clutch release cylinder with the 2 bolts.

Torque: 13 Nm (9 ft. lbs.)

7. A/T: INSTALL CROSS SHAFT





8. INSTALL FRONT EXHAUST PIPE
a. Install 2 new gaskets and the front exhaust pipe assembly with new 3 nuts.

Torque: 62 Nm (46 ft. lbs.)

b. Install the support bracket with the 2 bolts.

Torque: 39 Nm (29 ft. lbs.)

c. Connect the clamp and tighten the clamp bolt.

Torque: 19 Nm (14 ft. lbs.)

d. Connect a new gasket and the front exhaust pipe assembly to the Three-Way Catalytic Converter (TWC) with the 2 bolts and retainer.

Torque: 39 Nm (29 ft. lbs.)

e. Connect the 2 heated oxygen sensor connectors.
9. CONNECT SPEEDOMETER CABLE
10. INSTALL PROPELLER SHAFT





11. INSTALL STABILIZER BAR
a. Place the stabilizer bar in position and install both stabilizer bar bushings and brackets to the frame.
b. Torque the stabilizer bar mounting bolts.

Torque: 30 Nm (22 ft. lbs.)

c. Connect the stabilizer bar on both sides to the lower arms with brackets, cushions and new nuts as shown.





d. Torque the nuts.

Torque: 13 Nm (9 ft. lbs.)

12. M/T: INSTALL SHIFT LEVER ASSEMBLY





a. Install baffle and shift lever assembly with the 6 bolts.
b. Install the shift lever boot with the 4 screws.
c. Install the shift lever knob.





13. CONNECT WIRES AND CONNECTORS
a. Push in the engine wire through the cowl panel.
b. Connect the 4 engine wire clamps
c. Connect these wires and connectors:
- Ground strap to cowl top panel
- Igniter connector
d. Connect 2 connectors to cowl wire.





e. Connect 4 connectors to the ECM.
f. Install the ECM with the 3 bolts.
14. INSTALL FRONT DOOR SCUFF PLATE AND COWL SIDE TRIM
a. Install the cowl side trim with the clip.
b. Install the front door scuff plate with the 4 screws.
15. CONNECT GENERATOR WIRE
a. Connect the generator connector.
b. Connect the generator wire with the nut.
c. Connect the wire harness clip to the generator.





16. CONNECT POWER STEERING PUMP
a. Connect the power steering pump to the bracket with the 2 bolts.

Torque: 58 Nm (43 ft. lbs.)

b. Using Special Service Tools (SST), install the power steering pump pulley with the nut.
SST 09960 - 10010 (09962 - 01000, 09963 - 01000)

Torque: 43 Nm (32 ft. lbs.)

17. CONNECT HOSES
Connect these hoses:





- Fuel return hose
- Fuel inlet hose





- Brake booster vacuum hose
- EVAP hose
- 2 power steering hoses





18. CONNECT HEATER HOSES
19. w/ A/C: INSTALL A/C COMPRESSOR AND BRACKET





a. Install the A/C compressor bracket with the 4 bolts.

Torque: 44 Nm (32 ft. lbs.)

b. Install the A/C compressor with the 4 bolts.

Torque: 25 Nm (18 ft. lbs.)

c. Connect the A/C compressor connector.
20. INSTALL INTAKE AIR CONNECTOR





a. Install the intake air connector with the 2 bolts and hose clamp.

Torque: 18 Nm (13 ft. lbs.)

b. Connect the 2 air hoses.
21. M/T: CONNECT ACCELERATOR CABLE TO THROTTLE BODY
A/T: CONNECT ACCELERATOR AND THROTTLE CABLES TO THROTTLE BODY
22. INSTALL AIR CLEANER CASE
a. Install the air cleaner case with 3 bolts.
b. Install the air cleaner element.
23. INSTALL MASS AIR FLOW (MAF) METER, RESONATOR AND AIR CLEANER CAP
a. Connect the air cleaner hose clamp.
b. Install the air cleaner cap, MAF meter and resonator with the 4 clips.
c. Connect the MAF meter connector, Intake Air Temperature (IAT) sensor connector and wire clamp.
24. INSTALL RADIATOR
25. INSTALL RADIATOR RESERVOIR TANK
26. FILL WITH ENGINE OIL
27. FILL WITH ENGINE COOLANT
28. FILL TRANSMISSION OIL
29. INSTALL BATTERY
30. START ENGINE AND CHECK FOR LEAKS
31. CHECK IGNITION TIMING
32. INSTALL ENGINE UNDER COVER
Install the engine under cover with the 4 bolts.
33. INSTALL HOOD
34. VEHICLE ROAD TEST
Check for abnormal noise, shock, slippage, and smooth operation.
35. RECHECK ENGINE COOLANT AND ENGINE OIL LEVELS