Engine Installation

Engine Installation





1. Install the accessory brackets. 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.

NOTICE: Reinstall the mounting bolts/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.





4. Install the front sub-frame. Align the reference marks on the front sub-frame. then tighten the bolts.





5. Install the transmission lower front mount and transmission lower rear mount on the front subframe.





6. Install the rear mount on the front sub-frame.
7. Lower the hoist.





8. Tighten the front mount bracket support nut.





9. Install the side engine mount bracket, then tighten the mounting bolts in the numbered sequence shown.
10. Remove the chain hoist from the engine.
11. Raise the hoist to full height.





12. Install the steering gearbox.





13. Tighten the Power Steering (P/S) hose clamp mounting bolts (A), and install the harness clamp (B).





14. Install the stiffeners.





15. Tighten the P/S hose clamp mounting bolt (A), and install the P/S hose in the clamps (B).
16. 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.
17. Connect the suspension lower arm ball joints.
18. Connect the stabilizer links.





19. Install exhaust pipe A (A); use new gaskets (B) and new self locking nuts (C).
20. Connect the primary Heated Oxygen Sensor (primary HO2S) connector (D).





21. Install the control lever (A) with the shift cable on the control shaft. Do not bend the shift cable any more than is necessary to install the control lever.
22. Install the lock bolt (B) with a new lock washer (C), then bend the lock tab of the lock washer.
23. Install the shift cable cover (D), then install the shift cable holder (E) on the shift cable cover.





24. Install the splash shield.
25. Install the front tires/wheels.
26. Lower the hoist.





27. Install the upper radiator hose (A) and lower radiator hose (B).
28. Install the water bypass hoses (c) ('99-01 models).





29. Install the heater hoses.





30. Install the Automatic Transmission Fluid (ATF) cooler hoses.





31. Install the starter cable (A) and harness clamp (B).
32. Install the alternator-compressor belt.
33. Loosely install the P/S pump and P/S pump belt.
34. Adjust the P/S pump belt (see step 3).





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





36. Push in the Powertrain Control Module (PCM) connectors, Install the grommet (A), then tighten the grommet mounting nuts (B).
37. Install the harness clamps (c).





38. Connect the PCM connectors.








39. Install the brake booster vacuum hose (A).
40. Install the vacuum hose (B) ('99-01 models).








41. Install the fuel feed hose (A) and fuel return hose (B), using new washers (C).

42. Install the Evaporative Emission (EVAP) canister hose (D) ('02 model).
43. Install the cruise control cable, then adjust the cable.
44. Install the throttle cable, then adjust the cable.





45. Install the battery base.





46. Install the ground cable (A), relay box bracket (B) and harness clamp (C).





47. Connect the engine wire harness connectors on the left side of the engine compartment.








48. Install the intake air duct (A), then install the vacuum hose(s) (B) and breather pipe (C).
49. Install the EVAP canister hose (D) ('99-01 models) or vacuum hose (D) ('02 model).





50. Install the ignition coil cover (A) and intake manifold cover (B) ('02 model).
51. Install the battery. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion.
52. Refill the engine with engine oil.
53. Refill the automatic transmission with ATF for '99-01 models or '02 model.
54. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open.
55. Move the shift lever to each gear, and verify that the A/T gear position indicator follows the transmission range switch.
56. Inspect for fuel leaks. Turn the ignition switch ON (II) (do not operate the starter) so 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.
57. Inspect the idle speed.
58. Inspect the ignition timing.
59. Check the wheel alignment.
60. Enter the anti-theft code for the radio, then enter the customer's radio station presets.