Engine Installation

1.Install the engine and accessory brackets, and tighten their bolts to the specified torques.

 

2.Attach the chain hoist to the engine as shown.

 

3.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.


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

 

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

 

6.Install the ground cable (D).

7.Install the transmission upper mount bracket (A), and tighten the new bolts, then loosely tighten the mounting bolt (B).

 

8.Remove the chain hoist from the engine.

9.Raise the vehicle on the hoist to full height.

10.Install the lower torque rod (A), then tighten the new bolts (B), and loosely tighten the new bolt (C).

 

11.Lower the vehicle on the hoist.

12.Tighten the side engine mount mounting bolts/nuts in the numbered sequence shown.

 

13.Tighten the transmission upper mount/bracket mounting bolts/nuts in the numbered sequence shown.

 

14.Raise the vehicle on the hoist to full height.

15.Tighten the lower torque rod mounting bolt.

 

16.Tighten the new bolts securing the transmission lower mount.

 

17.Lower the vehicle on the hoist.

18.Install the upper torque rod (A), then tighten the new bolts in the numbered sequence shown.

 

19.Raise the vehicle on the hoist to full height.

20.Install the intercooler intake pipe (A) to the turbocharger outlet hose (B), then install the intercooler intake pipe bracket (C).

 

21.Loosely tighten the intercooler intake pipe mounting bolts (D). Make sure the mark (E) of the intercooler intake pipe contacts with the turbochager outlet hose end.

22.Tighten the intercooler intake pipe mounting bolts, and secure the turbochager outlet hose with the band (F), then install the intercooler intake hose (G), and secure the hose with band (H).

23.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.

24.Connect the suspension lower arm ball joints.

25.Connect the stabilizer links.

26.Install the propeller shaft on the transfer assembly.

27.Install exhaust pipe A. Use new gaskets (B) and new self locking nuts (C).

 

28.Install the splash shield.

 

29.Install the front wheels.

30.Lower the vehicle on the hoist.

31.Install the A/C compressor.

 

32.Install the heater hoses.

 

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

 

34.Install the drive belt.

35.Install the expansion tank (A), then install the harness clamp (B) and water bypass hose (C).

 

36.Install the intercooler.

37.Install the radiator.

38.Push the engine wire harness connectors through the bulkhead, then install the grommet (A), and harness clamps (B).

 

39.Connect the accelerator pedal position (APP) sensor connector (A).

 

40.Install the harness clamps (B) and ground cable (C).

41.Connect the engine wire harness connectors (A), then install the connector to the bracket.

 

42.Install the harness clamp (B).

43.Install the glove box stops.

44.Connect the engine control module (ECM) connectors.

 

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

 

46.Install the fuel feed hose.

 

47.Install the intercooler outlet hose.

 

48.Install the shift cable and select cable.

49.Install the clutch slave cylinder, and clutch line bracket mounting nut.

50.Install the harness connector bracket (A) to the under-hood fuse/relay box, then connect the harness connectors (B).

 

51.Install the glow control module (C).

52.Install the battery cables (D) to the under-hood fuse/relay box.

53.Install the battery base bracket (A), then install the clutch line bracket (B).

 

54.Install the intake air duct.

 

55.Install the battery base (A), then install the harness clamps (B).

 

56.Install the air cleaner housing.

57.Install the engine cover.

 

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

59.Check that the transmission shifts into gear smoothly.

60.Refill the engine with engine oil.

61.Refill the transmission with fluid.

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

63.Do the fuel system bleed procedure.

64.Do the ECM reset procedure.

65.Inspect the idle speed.

66.Enter the anti-theft codes for the radio and the navigation system, then enter the customer's audio presets.

67.Do the power window control unit reset procedure.

68.Set the clock.