Engine Installation

1.Install the accessory brackets, and tighten their bolts 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 subframe (A). Align the reference lines (B) on the subframe with the bolt head center, then tighten the bolts.

 

5.Tighten the rear mount mounting bolts.

 

6.Loosely tighten the front mount mounting bolt.

 

7.Lower the vehicle on 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.Raise the vehicle on the hoist to hull height.

11.Loosen the front engine mount bracket mounting bolt, then tighten it to the specified torque.

 

12.Lower the vehicle on the hoist.

13.Remove the chain hoist from the engine.

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

15.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.

16.Connect the suspension lower arm ball joints.

17.Connect the stabilizer links.

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

19.Install the shift cable (A/T):


20.Install three way catalytic converter (TWC) assembly (A), use new gaskets (B), and new self locking nuts (C).

 

21.Connect the primary heated oxygen sensor (primary HO2S) connector (D) (K20A4 engine (KU, KZ, FO, PH, MA, KN, KM, IN models)), or air fuel ratio sensor connector (D) (K24A1, K20A4 (KE, KG, KS models) engines).

22.Connect the secondary heated oxygen sensor (secondary HO2S) connector (E) (K24A1, K20A4 (KE, KG, KS models) engines), (F) (K20A4 engine (KU, KZ, FO, PH, MA models)).

23.Install the lower radiator hose.

 

24.Tighten the automatic transmission fluid (ATF) filter mounting bolt (A), and install the ATF cooler hoses (B) (A/T).

 

25.Install the splash shield.

 

26.Install the front tyres/wheels.

27.Lower the vehicle on the hoist.

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

 

29.Install the power steering (P/S) pump.

 

30.Install the drive belt.

31.Push the engine control module (ECM)/powertrain control module (PCM) connectors through the bulkhead, then install the grommet(A) and harness clamps (B).

LHD models: 

RHD models: 

32.Connect the accelerator pedal position (APP) sensor connector (C).

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

LHD models: 

RHD models: 

34.Install the brake booster vacuum hose (A) and the evaporative emission (EVAP) canister hose (B).

 

35.Connect the fuel feed hose:


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

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

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

 

39.Connect the subfuse/relay box connector (C).

40.Install the ground cable(A).

 


41.Install the intake air duct.

 

42.Install the air cleaner housing (A) and connect the intake air temperature (IAT) sensor connector (B).

 

43.Install the breather hose (C) and intake air bypass control thermal valve tube (D).

44.Install the intake manifold cover.

 

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

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

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

48.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.

49.Refill the engine with engine oil.

50.Refill the transmission with fluid:


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

52.K24A1, K20A4 (KE, KG, KS models) engines. Do the crankshaft position (CKP) pattern clear/CKP pattern learn procedure.

53.Do the power window control unit reset procedure.

54.Inspect the idle speed:


55.Inspect the ignition timing.

56.Check the wheel alignment.

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

58.Set the clock.