## Engine Installation

1. | 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.

2. | Install the front subframe (A), then secure the under covers with the clips (B).

3. | Install the left front mount/bracket assembly.

4. | Install the rear mount mounting bolts.

5. | Lower the hoist.

6. | Install the side engine mount/bracknt assembly (A), then tighten the mounting bolts and support nuts in the numbered sequence shown.

7. | Install the ground cable (B).

8. | Install the transmission mount bracket (A), then tighten the support bolt/nuts and mounting bolt in the numbered sequence shown.

9. | Install the ground cable (B).

10. | Remove the chain hoist from the engine.

11. | Raise the hoist to full height.

12. | Install the steering gearbox on the front subframe.

13. | 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.

14. | Connect the suspension lower arm ball joints.

15. | Connect the stabilizer links.

16. | Install the three way catalytic converter (TWC) (A); use new gaskets (B) and new self locking nuts (C).

17. | Connect the primary heated oxygen sensor (primary HO2S) connector (D).

18. | Connect the secondary heated oxygen sensor (secondary HO2S) connector (E).

19. | If the A/C compressor is equipped, install the condenser fan shroud.

20. | Install the A/C compressor (A), then connect the compressor clutch connector (B).

21. | Install the splash shield.

22. | Lower the hoist.

23. | Install the upper radiator hose (A) and lower radiator hose (B).

24. | Install the heater hoses.

25. | Install the select cable (A) and shift cable (B) using the plastic washers (C), washers (D), and new cotter pins (E).

26. | Install the clutch slave cylinder (A) and clutch line bracket mounting bolt (B).

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

28. | Install the battery cables (A) on the under-hood fuse/relay box, then install the harness clamp(s) (B). LHD models: RHD models:

29. | Connect the wire harness connector (C).

30. | Push the engine control module (ECM) connectors through the bulkhead, then install the grommet (A). LHD models: RHD models:

31. | Install the harness clamps (B).

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

33. | Connect the ECM connectors (A) and main wire harness connector (B). LHD models: RHD models:

34. | Install the battery base (A), then install the harness clamps (B).

35. | Install air cleaner housing.

36. | Install the battery.

37. | Install the fuel feed hose.

38. | Install the drive belt and adjust it, refer to the 2002 Jazz/Fit Shop Manual.

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

40. | Check that the transmission shifts into gear smoothly.

41. | 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.

42. | Refill the engine with engine oil, refer to the 2002 Jazz/Fit Shop Manual.

43. | Refill the transmission with fluid.

44. | Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open, refer to the 2002 Jazz/Fit Shop Manual.

45. | Perform the ETCS learn procedure.

46. | Inspect the idle speed.

47. | Inspect the ignition timing.

48. | Check the wheel alignment.