Carefully lower the engine into the engine bay. Make sure it clears
everything sticking out on its way down.
Align the engine so the passenger side mount can be attached to the body
and tighten the bolts to 54 ft-lbs.
Install the support bar across the fenders and take the weight off the
crane. The engine will now rest on the passenger side mount and the
Now is the good time to
install the transmission.
It can be done at a later stage, but it's easier without having coolant
hoses and wires in the way. It also allows to install the subframe right
away and get rid of the support bar.
Attach the steering pump with three 13 mm bolts. The bolt location is rather
awkward, and in most cases there's only enough room for a 1/6 or even 1/12
turn of a spanner at a time.
Bolt the A/C compressor to the engine (three long 16 mm bolts). Plug
the A/C clutch wire into its connector on the radiator. Attach oil cooler
lines to the oil filter housing (22 mm wrench).
Lock the tensioner using a long ½" extension and a 2 mm pin
and fit the accessory belt. The picture shows a short belt configuration
with the middle idler pulley bypassed.
Install the airbox and connect the ribbed hose to the turbo inlet pipe.
Attach the boost pressure control valve to its proper location (two T25
screws) and route the cable around the airbox.
Feed the ECU harness back through the hole in the firewall and plug it
with the rubber grommet.
Here's a custom Nordic stage4 ECU I'm using with my freshly built 2.3L
Install the ECU (if you had it removed) and connect the wiring harnesses.
Re-connect the fuel lines, the fuel tank vent line to the throttle body
and the EVAP valve harness.
Install the cruise control unit (two plastic 10 mm nuts).
Attach the cruise control and accelerator cables to the arm on the throttle
body. Bolt on the brake booster vacuum line.
Connect the vacuum hose and the cable to the manifold pressure sensor
(this picture shows the strut bar installed already).
Lower rad hose
Install the lower radiator hose. I'm using a newer style nose here,
since it needs to clear the turbo hose to the cross-flow intercooler.
Attach the remaining coolant hoses: two heater core hoses, upper radiator
hose, upper and lower expansion tank hoses.
Connect the intercooler inlet hose to the compressor housing on the turbo.
Tighten the clamps well.
Install the delivery pipe from the intercooler to the throttle body.
Tighten the 13 mm bolt that holds it to the engine head.
Bolt the downpipe to the turbo and screw in the O2 sensor (or both if you
have an OBD II car).
steps, fill the fluids and install the battery.