Engine Installation: 1. Engine installation is generally reverse of removal. Make certain all hardware is tightened to appropriate torque specification. 2. Prior to installing the engine, inspect the condition of the rubber on the engine mounts. Replace the engine mounts if the rubber is damaged. 3. Mount the transaxle back onto the engine. Tighten the bolts with specified torque. 4. Install the starter motor and engine wiring harness along with its mounting brackets. 5. With the vehicle raised on the vehicle lift hoist, place the engine underneath the vehicle, aligned with the engine compartment. 6. Slowly and carefully raise engine into engine bay. 7. Connect the lifting crane to the engine with a chain / belt. Raise the hoist slightly to apply lifting tension to the engine. 8. Secure the engine in the vehicle by attaching A, B and then C mount in sequence along with brackets. Tighten the mounting bracket hardware at specified torque. 9. With the engine attached to the crane, remove the support stand. Remove the chain / belt after engine mounts 10. are secure. Install the left and right driveshaft assemblies. 11. Connect the gearshift linkage, clutch cable to 12. the engine and transaxle. Connect the engine wiring harness. 13. Connect the cooling system reservoir hoses. 14. Verify the cooling system drain is closed on the radiator. Install the cooling system hoses to the engine, radiator and heater core. To connect the exhaust front pipe tighten the 15. flange near Catcon and connect at rear end. Install the air filter assembly and intake system 16. hoses to the engine. Connect the vacuum hose connected between 17. brake booster to vacuum pump. Connect all the hoses connected between 18. radiator and engine. Connect the fuel lines to the engine. 19. Install the Battery Plate, Battery and ECU. 20. Connect the engine wiring harness connection 21. with ECU. Add the appropriate quantity of Engine oil, 22. Transaxle oil and coolant with respective systems. Connect the battery positive cable and then the 23. battery negative cable. Crank the engine several times without 24. allowing the vehicle to start. This allows the oil and coolant to flow through engine. Start the engine and verify the oil pressure light 25. on the instrument cluster goes out. Stop the engine immediately if the light fails to extinguish. Allow the engine to run for several minutes, 26. checking for fluid levels and leakage. CAUTION Use care when lowering the vehicle body to the engine and transaxle assembly. Verify all the engine and other components will not make direct contact or vehicle damage will occur. NOTE While tightening of B mount, use 12 mm 3 no’s of sockets on consecutive 3 mounting bolts as shown in fig. 1.2L REVOTRON CNG PHASE-2 ENGINE 109
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