Attaching Engine Components

AFTER ASSEMBLY
1. INSTALL EGR COOLER
Install a new gasket and the EGR cooler with the 3 bolts and 2 nuts.
Torque: 9 N.m (90 kgf.cm, 78 in..lbf)






2. INSTALL ENGINE COOLANT DRAIN UNION
(a) Apply seal packing to 2 or 3 threads. Seal packing:
Part No.08826-00100 or equivalent
(b) Install the drain union. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)

HINT: After applying the specified torque, rotate the drain union clockwise until its drain port is facing downward.

3. INSTALL WATER SEAL PLATE
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the seal plate and cylinder block.
- Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove.
- Thoroughly clean all components to remove all the loose material.
- Using a non-residue solvent, clean both sealing surfaces.
(b) Apply seal packing to the seal plate as shown in the illustration. Seal packing: Part No.08826-00100 or equivalent
- Install a nozzle that has been cut to a 3 - 5 mm (0.12 - 0.20 in.) opening.
- Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
- Immediately remove nozzle from the tube and reinstall cap.
(c) Install the seal plate with the 2 nuts.
Torque: 18 N.m (180 kgf.cm, 13 ft.lbf)
4. INSTALL OIL FILTER UNION
Torque: 30 N.m (310 kgf.cm, 22 ft.lbf)
5. INSTALL OIL FILTER
(See oil and filter replacement in Lubrication System)
6. INSTALL OIL PUMP
(See oil pump installation in Lubrication System)
7. INSTALL NO.1 OIL PAN
(See oil pump installation in Lubrication System)
8. INSTALL OIL STRAINER
(See oil pump installation in Lubrication System)
9. INSTALL NO.2 OIL PAN
(See oil pump installation in Lubrication System)
10. INSTALL WATER PUMP
(See water pump installation in Cooling System)
11. INSTALL WATER INLET HOUSING
(a) Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surfaces of the water inlet housing and cylinder block.
- Using a razor blade and gasket scraper. remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
- Thoroughly clean all components to remove all the loose material.
- Using a non-residue solvent, clean both sealing surfaces.






(b) Apply seal packing to the water inlet housing as shown in the illustration.
Seal packing: Part No.08826-00100 or equivalent
- Install a nozzle that has been cut to a 3 - 5 mm (0.12-0.20 in.) opening.

HINT: Avoid applying an excessive amount to the surface.
- Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
- Immediately remove nozzle from the tube and reinstall cap.






(c) Install the water inlet housing with the 8 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes, in the sequence shown.
Torque: 8 N.m (80 kgf.cm. 69 in..lbf)
(d) Install the engine wire band.
(e) Install the engine wire clamp.






12. INSTALL KNOCK SENSORS
(a) Using SST, install the 2 knock sensors. SST 09816-30010
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)
(b) Connect the 2 knock sensor connectors.
13. INSTALL NO.2 IDLER PULLEY BRACKET Torque: 28 N.m (290 kgf.cm, 21 ft.lbf)
14. INSTALL A/C COMPRESSOR HOUSING BRACKET Torque: 25 N.m (250 kgf.cm, 18 ft.lbf)
15. INSTALL OIL PRESSURE SWITCH
(See oil pressure check in Lubrication System)
16. INSTALL GENERATOR BRACKET AND ADJUSTING BAR
Install the generator bracket and adjusting bar with the 3 nuts.
Torque: 43 N.m (440 kgf.cm. 32 ft.lbf)
17. INSTALL GENERATOR
(See generator installation Charging System)
18. INSTALL CYLINDER HEAD
(See cylinder head installation)
19. INSTALL TIMING PULLEYS AND BELT
(See timing belt installation)
20. REMOVE ENGINE STAND






ENGINE & TRANSAXLE ASSEMBLY
1. INSTALL DRIVE PLATE
(a) Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive: Part No.08833-00070, THREE BOND 1324 or equivalent






(b) Install the front spacer. drive plate and rear plate on the crankshaft.
(c) Install and uniformly tighten the 8 bolts in several passes, in the sequence shown.
Torque: 83 N.m (850 kgf.cm. 61 ft.lbf)






2. INSTALL TRANSAXLE TO ENGINE
A. Install transaxle
(a) Attach the transaxle to the engine.
(b) Install the ground strap and 8 bolts.
Torque:
14 mm head 37.2 N.m (380 kgf.cm, 27 ft.lbf)
17 mm head 64 N.m (650 kgf.cm, 47 ft.lbf)






(c) Install the RH exhaust manifold stay with the bolt and nut.
Torque: 20 N.m (200 kgf.cm, 15 ft.lbf)
(d) Install the LH exhaust manifold stay with the bolt and nut.
Torque: 20 N.m (200 kgf.cm, 15 ft.lbf)
B. Install torque converter clutch bolts
(a) Apply adhesive to 2 or 3 threads of the bolt.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent






(b) Hold the crankshaft pulley bolt with a wrench. and install the 6 bolts evenly.
Torque: 41 N.m (420 kgf.cm. 30 ft.lbf)

HINT: First install the dark green colored bolt, then install the other bolts.

(c) Install the flywheel housing under cover with the 2 bolts.
Torque: 7.8 N.m (80 kgf.cm, 69 in..Ibf)
3. CONNECT ENGINE WERE TO TRANSAXLE
Connect these connectors and clamps:
- VSS connector
- PNP switch connector
- Solenoid connector
- Direct clutch speed sensor connector
- 2 engine wire clamps to bracket
4. INSTALL STARTER
(See starter installation in Starting System)
5. INSTALL OIL DIPSTICK GUIDE AND DIPSTICK FOR TRANSMISSION
(a) Install a new 0-ring to the dipstick guide.
(b) Apply soapy water to the 0-ring.
(c) Connect the dipstick guide end to the dipstick tube of the oil pan.
(d) Install the dipstick guide with the bolt.
(e) Install the dipstick.