Engine Installation

Special Tools Required
Sub hanger stay (  07MAK-PY30100)
 

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

2.

Position the engine/transmission assembly under the vehicle. Be sure that they are properly aligned. Carefully lower the vehicle until the engine and transmission are properly positioned in the engine compartment. Make sure the vehicle is not resting on any part of the engine or transmission. Lift and support the engine with a engine tilt hanger set and carefully raise the engine/transmission assembly into place. NOTE: Reinstall the mounting bolts/support nuts in the sequence given in the following steps. Failure to follow this sequence may cause excessive noise and vibration, and reduce engine mount life.

3.	Loosen the upper torque rod mounting bolt (A).

4.	Tighten the new side engine mount bracket mounting bolt and nut.

5.	Tighten the new transmission mounting bolt and nuts (A). M/T  A/T

6.	Install the ground cable (B).

7.	Make sure the hoist brackets are positioned properly. Raise the hoist to full height.

8.	Support the front subframe with the wood piece and a jack, and lift it up to the body.

9.	Loosely install the new subframe mounting bolts.

10.	Align all reference marks (A) on the front subframe with the body (B), then tighten the bolts on the front subframe to the specified torque.

11.	Remove the jack and front subframe adapter.

12.	Tighten the new mid-stiffener mounting bolts on both sides.

13.	Install the lower torque rod, then tighten the new lower torque rod mounting bolts in the numbered sequence shown. M/T  A/T

14.	Make sure the hoist brackets are positioned properly. Lower the vehicle on the hoist.

15.	Disconnect the chain hoist from the engine/ transmission assembly.

16.	Tighten the upper torque rod mounting bolt.

17.	Remove the engine hanger plate (A), then install the ground cable (B).

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

19.

Position the ‘‘FR'' mark to the front of the vehicle, then install the steering gearbox bracket. NOTE: 19 describe steering gearbox removal for the LHD model with hydraulic assisted power steering; RHD model is symmetrical. If you remove the gearbox on the model with electrical power steering, go to 23

20.	Install the stiffener (A), then tighten the steering gearbox mounting bolt (B) and stiffener mounting bolt (C).

21.	Install the bolt (D) securing the power steering fluid line bracket.

22.	Install the stiffener (A), then tighten the steering gearbox mounting bolt (B) and stiffener mounting bolt (C).

23.	Install the bolt (A) securing the power steering fluid line bracket (B), and install the power steering fluid line (C) on the clamp (D).

24.	Install the steering gearbox bracket mounting bolts. NOTE: 24 describe gearbox removal for electrical power steering model.

25.	Install the stiffener (A), then tighten the steering gearbox mounting bolt (B) and stiffener mounting bolt (C).

26.	Install the stiffener (A), then tighten the steering gearbox mounting bolt (B) and stiffener mounting bolt (C).

27.	Install the bolt securing the harness clamp bracket.

28.	Install the P/S pump (With P/S).

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

30.	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.

31.	Connect the lower arms to the knuckles.

32.	Connect the stabilizer links.

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

34.	Install the splash shield.

35.	Lower the vehicle on the hoist.

36.	Install the heater hoses.

37.	Install the A/C compressor (A) (With A/C).

38.	Connect the A/C compressor clutch connector (B), then install the harness clamp (C) (With A/C).

39.	Install the drive belt.

40.	Install the radiator.

41.	Install the clutch slave cylinder and clutch line bracket mounting bolt (M/T): 5-Speed 6-Speed

42.	Install the shift cable (M/T): 5-Speed 6-Speed

43.	Install the harness holder (A) and harness clamp (B) (M/T).

44.	Connect the engine control module (ECM)/ powertrain control module (PCM) connectors (A) and engine wire harness connectors (B).

45.	Install the harness clamps (C).

46.	Install the ECM/PCM (A), then install the ECM/PCM cover (B).

47.	Install the battery cables (A) to the under-hood fuse/ relay box.

48.	Install the harness clamps (B).

49.	Install the evaporative emission (EVAP) canister hose (A), the brake booster vacuum hose (B), and the power steering (P/S) hose clamp (C).

50.	Connect the fuel feed hose, then install the quick-connect fitting cover (A).

51.	Install the injector cover.

52.	Install the under-cowl panel.

53.	Install the air cleaner housing.

54.	Install the front wheels.

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

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

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

58.	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.

59.	Refill the engine with engine oil.

60.	Refill the transmission with fluid: Manual transmission 5-Speed 6-Speed Automatic transmission

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

62.	Do the ECM/PCM reset procedure.

63.	Do the crankshaft position (CKP) pattern clear/CKP pattern learn procedure.

64.	Inspect the idle speed.

65.	Inspect the ignition timing.

66.	Check the wheel alignment.

67.	Do the power window control unit reset procedure.

68.	Set the clock.

69.	Enter the anti-theft code for the radio or the navigation system, then enter the customer's audio presets.