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.



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.


3.Install the A/C compressor (A), and connect the compressor clutch connector (B).

 

4.Install the sub-frame (A). Align the reference lines (B) on the sub-frame with the bolt head center, then tighten the bolts.

 

5.Tighten the front mount mounting bolt.

 

6.Tighten the rear mount mounting bolts.

 

7.Lower the hoist.

8.Tighten the upper bracket mounting bolt and nut.

 

9.Tighten the transmission mount bracket support bolt/nuts.

M/T: 

A/T: 

10.Remove the chain hoist from the engine.

11.Raise the hoist to full height.

12.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.

13.Connect the suspension lower arm ball joints

14.Connect the stabilizer links.

15.Install the propeller shaft to the transfer (4WD).

16.Install the shift cable (A/T).

17.Install Three Way Catalytic Converter (TWC) assembly (A) (K20A4, K24A1 engines) or exhaust chamber (A) (K20A5 engine); use new gaskets (B) and new self locking nuts (C).

 

18.Connect the primary Heated Oxygen Sensor (primary HO2S) connector (D) (Except K20A5 engine).

19.Connect the secondary Heated Oxygen Sensor (secondary HO2S) connector (E) (KE, KG, KS, KR, KU, KZ, KQ, FO models).

20.Install the lower radiator hose.

 

21.Tighten the Automatic Transmission Fluid (ATF) filter mounting bolt (A), and install the ATF cooler hoses (B) (A/T).

 

22.Install the splash shield.

 

23.Lower the hoist.

24.Install the upper radiator hose (A) and heater hoses (B).

 

25.Install the Power Steering (P/S) pump.

 

26.Install the drive belt.

27.Install the throttle cable, then adjust the cable.

28.Install the cruise control cable, then adjust the cable.

29.Push the Engine Control Module (ECM)/Power train Control Module (PCM) connectors through the bulkhead, then install the grommet(A).

LHD models: 

RHD models: 

30.Install the harness clamps (B).

31.Connect the ECM/PCM connectors (A) and main wire harness connector (B).

LHD models: 

RHD models: 

32.Install the brake booster vacuum hose (A) and the Evaporative Emission (EVAP) canister hose (B).

 

33.Connect the fuel feed hose.

34.Install the select cable and shift cable (M/T).

35.Install the clutch slave cylinder and clutch line bracket (M/T).

36.Install the battery cables (A) on the under-hood fuse/relay box, then install the harness clamps (B).

 

37.Install the ground cable (C).

38.Install the intake air duct.

 

39.Install the air cleaner housing (A) and connect the Intake Air Temperature (IAT) sensor connector (B).

 

40.Install the breather hose (C).

41.Install the intake manifold cover.

 

42.Install the battery. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion.

43.Move the shift lever to each gear, and verify that the A/T gear position indicator follows the transmission range switch (A/T).

44.Check that the transmission shifts into gear smoothly (M/T).

45.Inspect for fuel leaks. Turn the ignition switch ON (II) (do not operate the starter) so that the fuel pump runs for about 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.

46.Refill the engine with engine oil.

47.Refill the transmission with fluid:


48.Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.

49.Inspect the idle speed.

50.Inspect the ignition timing.

51.Check the wheel alignment.