Engine Installation
  1. Install the accessory brackets and tighten their bolts to the specified torques.
  1. 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.
  1. Loosen the upper torque rod mounting bolt (A).
  1. Tighten the new side engine mount bracket mounting bolt and nut.
  1. Tighten the new transmission mounting bolt and nuts (A).
  1. Install the ground cable (B).
  1. Make sure the hoist brackets are positioned properly. Raise the hoist to full height.
  1. Support the front subframe with the wood piece and a jack, and lift it up to the body.
  1. Tighten the new subframe mounting bolts.
  1. Install the lower torque rod, then tighten the new lower torque rod mounting bolts in the numbered sequence shown.
  1. Make sure the hoist brackets are positioned properly. Lower the vehicle on the hoist.
  1. Disconnect the chain hoist from the engine/ transmission assembly.
  1. Tighten the upper torque rod mounting bolt.
  1. Remove the hanger (Commercially available tool).
  1. Raise the vehicle on the hoist to full height.
  1. Connect the connectors to the steering gearbox.
  1. 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.
  1. Install exhaust pipe A. Use new gaskets (B) and new self-locking nuts (C).
  1. Install the clutch line bracket mounting bolt (with i-SHIFT).
  1. Lower the vehicle on the hoist.
  1. Install the heater hoses.
  1. Install the A/C compressor (A) (with A/C).
  1. Connect the A/C compressor clutch connector (B), then install the harness clamp (C) (with A/C).
  1. Connect the shift cable actuator connectors and back-up light switch connector, then install the harness clamps (with i-SHIFT).
  1. Install the harness holder.
  1. Align the reference mark (A) on the steering joint and steering gearbox pinion shaft. Connect the steering joint (B) to the steering gearbox pinion shaft (C). Tighten the steering joint bolt.
  1. Install the steering joint cover (D).
  1. Connect the engine control module (ECM) connectors (A) and engine wire harness connectors (B).
  1. Install the harness clamps (C).
  1. Install the ECM (A), then install the ECM cover (B).
  1. Install the battery cables (A) to the under-hood fuse/relay box.
  1. Install the harness clamp (B).
  1. Install the evaporative emission (EVAP) canister hose (A) and the brake booster vacuum hose (B).
  1. Connect the fuel feed hose, then install the quick-connect fitting cover (A).
  1. Install the injector cover.
  1. Install the engine undercover.
  1. Install the battery.
  1. Install the front wheels.
  1. Install the battery. Clean the battery posts and cable terminals with sandpaper, then assemble them, and apply grease to prevent corrosion.
  1. Check that the transmission shifts into gear smoothly.
  1. 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.
  1. Set the clock.