Installation
Special Tools:
- Lifting Yokes tool No. 999 2810, or equivalent
- Lifting Yoke tool No. 999 5428, or equivalent
- Lifting Eyelet tool No. 999 5459, or equivalent
- Lifting Eyelet tool No. 999 5464, or equivalent
- Holder tool No. 999 5533, or equivalent
NOTE: For additional information on special tools and equipment used in this procedure, refer to "Tools For Engine Reconditioning". Tools and Equipment
Procedure
NOTE: Engines are equipped with a reinforced front lifting eyelet, which means that eyelets tools No. 999 5459 and 999 5464, or equivalent have been replaced by lift arm tool No. 998 9734, or equivalent. This lift arm is included in the kit for tool No. 999 2810, or its equivalent.
1. Install engine and transmission:
- Use lifting yokes tools No. 999 2810, 9999 5428 and lifting eyelets tools No. 999 5459 and 999 5464, or equivalents, as required.
- Adjust lifting yoke to balance engine.
- Ensure correct lifting angle throughout entire operation.
NOTE: Carefully ensure that power train is clear of body and any extra equipment.
2. Install engine wiring harness:
- Remove lifting eyelets and install extension arm mounting and spark plug cover.
- Connect all connectors, as previously noted.
1 Injectors
2 Temperature sensor (ECT)
3 Knock sensors (KS)
4 Generator (GEN)
5 A/C-compressor
6 Engine coolant fan (FC)
7 Starter motor
8 Oil pressure switch
9 Throttle (TP) potentiometer
10 Automatics
11 Reversing lights
12 Vehicle speed sensor (VSS)
13 Heated oxygen sensor (H02S)
14 Camshaft position (CMP) sensor
15 Mass air flow (MAF) sensor
16 Engine speed (RPM) sensor
17 Ground terminals
3. Install fuel distribution manifold:
- Grease injector O-rings.
- Tighten fuel distribution manifold.
- Remove holder tool No. 999 5533, or equivalent.
- Install fuel distribution manifold cover.
- Install fuel pipe mounting screws (upper and lower).
4. Install:
- P/S pump
- three radiator hoses
- auxiliaries belt
5. Mount A/C-compressor with two bolts screws in its bracket
- Lift up AC-compressor and mount in bracket with bolts.
6. Install:
- intake manifold bracket
- starter motor bracket
- front engine mount nut
- wiring conduit bracket
7. Install engine coolant fan
- (Remove shield from radiator)
- Lift in engine coolant fan with shroud.
- Install air intake.
- Tighten fan shroud to radiator.
- Control module cooling air duct.
Install both relays on fan shroud and connect connectors.
Clamp wiring.
8. Install ACC filter-bracket:
- Install rubber gear selector cable mounting.
Manual Transmission:
- Install gear selector cables in mountings on transmission.
- Pull clutch slave cylinder back through the front hole in the bracket.
- Install air filter bracket rubber mountings and tighten bracket.
Automatic Transmission:
- Connect connector.
- Install two oil cooler hoses.
9. Install:
- negative lead to transmission
- clutch slave cylinder, to transmission
- slave cylinder retaining ring
NOTE: Use a 24 mm wrench to hold slave cylinder when installing retaining ring.
10. Install:
- lower radiator hose to radiator
- hose from brake servo
- two heating hoses to firewall
- upper torque rod to engine with new bolts.
Tighten to 50 Nm (37 ft lb) and 90°
- throttle cable to throttle pulley
- rear engine mount upper nut
- Connect H02S wiring.
11. Install air cleaner (ACL):
- Install ACL and preheating hose.
- Connect connector and vacuum hoses to solenoid valve.
12. Install:
- all crankcase ventilation, throttle body (TB) and idle air control (IAC) valve hoses
- throttle pulley cover
- MAF connector
- HT lead between distributor and ignition coil
- battery shelf and battery with leads
NOTE: If the car has cruise control, vacuum hose and vacuum motor wiring must be connected before the battery shelf is screwed down.
13. Reinstall the following components:
1 Track rod ends to axle shafts
2 Nuts holding ball joints on control arms.
3 Torque rod screw on transmission (use new screw).
4 Two right engine mounting screws.
5 Right drive shaft and intermediate bearing cap to drive shaft in engine block.
6 Brake pipe/cable mounting screw.
7 Left drive shaft.
8 Exhaust pipe with seals, nuts and springs.
9 Two narrow black hoses from EVAP canister.
10 the white hose from the vacuum reservoir.
11 Right wing liner.
12 Left front wheel.
NOTE: Install splashguard and air baffle under engine.
14. Fill with coolant and engine oil:
- Coolant volume about: 7.20 l (7.6 US qt.).
- Oil capacity: including oil filter: 5.3 l (5.6 US qt.)
15. Carry out function check:
- Start engine, run until thermostat opens.
- Check for leaks.
- Check and if necessary adjust oil and coolant levels.
- Automatics: Check oil level in automatic transmission.