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.
| 1. | Position the engine under the vehicle. Attach the chain hoist to the engine, then lift the engine into position in the vehicle.
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| 2. | Install the front subframe (A), then secure the under covers with the clips (B).
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| 3. | Install the left front mount/bracket assembly.
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| 4. | Install the rear mount mounting bolts.
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| 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.
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| 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.
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| 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).
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| 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).
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| 21. | Install the splash shield.
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| 22. | Lower the hoist. |
| 23. | Install the upper radiator hose (A) and lower radiator hose (B).
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| 24. | Install the heater hoses.
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| 25. | Install the select cable (A) and shift cable (B) using the plastic washers (C), washers (D), and new cotter pins (E).
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| 26. | Install the clutch slave cylinder (A) and clutch line bracket mounting bolt (B).
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| 27. | Install the evaporative emission (EVAP) canister hose (A) and brake booster vacuum hose (B).
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| 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).
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| 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. |