Engine Installation

Install the accessory brackets and tighten their bolts to the specified torques. Install the engine/transmission into position in the vehicle. Reinstall the mounting bolts/support nuts in the sequence given. Failure to follow this sequence may cause excessive noise and vibration, and reduce bushing life. |

Install the side engine mount bracket (A), then loosely tighten the new bolts/nut (B), and loosely tighten the bolt (C). |

Install the transmission upper mount (A), then loosely tighten the new nuts (B), and loosely tighten the new bolt (C). |

Install the transmission upper mount bracket (A), and tighten the new bolts, then loosely tighten the mounting bolt (B). Raise the vehicle on the hoist to full height. |

Install the lower torque rod (A), then tighten the new bolts (B), and loosely tighten the new bolt (C). Remove the chain hoist from the engine. Lower the vehicle on the hoist. |

Tighten the side engine mount mounting bolts/nut in the numbered sequence shown. |

Tighten the transmission upper mount/bracket mounting bolts/nut in the numbered sequence shown. Raise the vehicle on the hoist to full height. |

Tighten the lower torque rod mounting bolt. |

Tighten the two bolts securing the transmission lower mount. Lower the vehicle on the hoist. |

Install the upper torque rod (A), then tighten the new bolts in the numbered sequence shown. Install the ground cable (B). Raise the vehicle on the hoist to full height. |

Install exhaust pipe A (A). Use new gaskets (B) and new self locking nuts (C). Install a new set ring on the end of each driveshaft, then install the driveshafts. Make sure each ring ‘‘clicks'' into place in the differential and intermediate shaft. Connect the suspension lower arm ball joints. Install the damper forks. Connect the stabilizer links. |

Install the splash shield. Install the front tyres/wheels. Lower the vehicle on the hoist. |

Install the A/C compressor. |

Install the A/C condenser fan shroud (A), then connect the A/C condenser fan motor connector (B). |

Install the upper radiator hose (A) and lower radiator hose (B). |

Install the heater hoses. |

Install the expansion tank. |

Install the power steering (P/S) pump (A), and the P/S hose clamp (B). Install the drive belt. |

Push the engine wire harness connectors through the bulkhead, then install the grommet (A) and harness clamps (B). Connect the accelerator pedal position (APP) sensor connector (C). |

Connect the engine wire harness connectors (A). Install the harness clamp (B). |

Install the fuel return hose (A) and brake booster vacuum hose (B). Install the fuel feed hose. |

Install the intercooler outlet hose. Install the select cable and shift cable. |

Install the clutch line bracket. Install the clutch slave cylinder and clutch line bracket mounting nut. |

Install the intercooler inlet pipe. |

Place the fuse/relay box bracket, then install the harness clamp (A) to the body. Install the harness clamps (B) and harness connector (C) to the fuse/relay box bracket. |

Tighten the four bolts (A) securing the fuse/relay box bracket and tighten the bolt (B) securing the intercooler inlet pipe. Install the under-hood fuse/relay box (C) to the fuse/relay box bracket. |

Connect the harness connectors (A). Install the glow control module (B) and harness clamps (C), then install the battery cables (D). |

Install the resonator (A), then install the air intake cover (B). |

Loosely install the bolts (A), then install the battery base (B). Tighten the bolts securing the battery base. Install the ground cable stay (C), harness clamp (D), and harness stay mounting bolt (E). Install the air cleaner housing. |

Install the engine cover. Install the battery. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion. Check that the transmission shifts into gear smoothly. Refill the engine with engine oil. Refill the transmission with fluid. Do the fuel system bleed procedure. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open. Do the ECM reset procedure. Do the power window control unit reset procedure. Inspect the idle speed. Enter the anti-theft codes for the radio and the navigation system, then enter the customer's radio station presets. Set the clock. |