Manual Transmision
1. Install engine and transmission assembly in vehicle as follows:
(a) Attach the engine hoist chain to the engine hangers.
(b) Lower the engine and transmission assembly into the engine compartment.
NOTE: Install the engine and transmission assembly carefully without damaging the shift lever retainer, the A/C compressor and power steering solenoid valve.
(c) Insert the stud bolts of the front engine mounting insulators into the stud bolt holes of the front suspension crossmember.
(d) Install the 2 nuts holding the engine front mounting insulators to the front suspension crossmember hand tight.
(e) Keep the engine level with a jack.
(f) Remove the hoist chain.
(g) Install the support member to the engine rear mounting insulator with the 4 nuts with the front mark facing forward hand tight.
(h) Install the 4 bolts holding the support member to the body, tighten to 25 Nm (19 ft. lbs.).
(i) Tighten the 4 nuts holding the support member to the engine rear mounting insulator to 13 Nm (10 ft. lbs.).
(j) Tighten the 2 nuts holding the engine front mounting insulators to the front suspension crossmember, to 59 Nm (43 ft. lbs.).
2. Install the clutch release cylinder, ground strap and transmission shift lever.
3. Install rear center floor crossmember brace, tighten to 13 Nm (9 ft. lbs.).
4. Install intermediate shaft.
(a) Remove the SST 09325-20010 from the yoke of the transmission.
(b) Insert the yoke into the transmission.
(c) Align the matchmarks on the flanges, and connect the propeller shaft with the 4 bolts, washers and nuts.
(d) Torque the bolts and nuts to 74 Nm (54 ft. lbs.).
(e) Temporarily install the center support bearing set bolts with the adjusting washers.
NOTE: Use the adjusting washers which were removed.
(f) Torque the bolts to 49 Nm (35 ft. lbs.), and inspect the joint angle.
5. Install the exhaust pipe heat insulator with the 4 bolts with the front mark facing forward.
6. Install No. 2 front exhaust pipe.
7. Install starter wire and fuel inlet hose.
(a) Install the ground strap to the transmission.
(b) Install the starter wire with the nut.
(c) Install the starter wire with the wire clamp.
(d) Install the fuel inlet hose with 2 new gaskets and the union bolt and torque to 29 Nm (22 ft. lbs.).
8. Install the pressure feed hose with the 2 clamp bolts.
9. Connect engine wire to cabin as follows:
(a) Push in the engine wire through the cowl panel.
NOTE: Be careful not to damage the engine wire.
(b) Connect these connectors:
- 2 connectors to ECM
- Connectors to ABS & TRAC ECU
- 2 connectors to TRAC ECU
- 4 connectors to connector cassette
- Connector to A/C control assembly
(c) Install the ECM with the nut.
(d) Install the ECM cover with the 2 nuts.
(e) Install the floor carpet.
(f) Install the scuff plate.
(g) Connect the connectors.
(h) Install the lower instrument panel finish panel and glove compartment door assembly with the 4 screws.
(i) Install the instrument panel under cover with the 2 clips.
10. Install the shift lever mounting bolts, boot, upper console plate and connect the following engine wire and hoses:
(a) Install the engine wire clamp with the 2 nuts.
(b) Install the bolt holding the engine wire protector to the water valve bracket.
(c) Install the bolt holding the engine wire protector to the body.
(d) Install the ground strap to the bracket on the body.
(e) Connect the VSV connector.
(f) Connect these hose:
- Heater water hose to water bypass pipe
- Heater water hose to heater water valve
- Vacuum hose (from VSV for heater water valve) to check valve
(g) Install the generator wire with the nut and cap.
(h) Connect the ignition coil connector and noise filter connector
(i) Install the engine wire with the 2 wire clamps.
(j) Connect the PS pressure switch connector.
(k) Install the ground strap on the cylinder block.
(l) Connect the PS solenoid valve connector and wire clamp.
(m) Using a 6 mm hexagon wrench, install the connector bracket with the bolt.
(n) Connect these connectors:
- 2 connectors to engine room main wire
- Igniter connector
- Theft deterrent horn connector
(o) Install the engine wire with the 2 wire clamps.
(p) Connect the fuel return hose to the fuel return pipe and engine oil dipstick guide clamp.
(q) Connect the brake booster vacuum hose to the union.
(r) Connect the EVAP hose to the No. 2 vacuum pipe.
11. Install the A/C compressor.
(a) Using an E10 torx socket, install the stud bolt and compressor. Torque the stud bolt to 26 Nm (19 ft. lbs.).
(b) Connect the compressor connector.
(c) Install the compressor with the nut and 2 bolts and torque to 52 Nm (38 ft. lbs.).
12. Install the PS pump.
(a) Install the pump bracket with the 2 bolts. Torque bolt "A" to 58 Nm (43 ft. lbs.) and 39 Nm (29 ft. lbs.) for bolt "B".
(b) Install the vane pump with the bolt and plate washer and torque to 52 Nm (38 ft. lbs.).
(c) Install the pump rear stay with the 2 bolts and torque to 39 Nm (29 ft. lbs.).
(d) Connect the PS air hose to No. 4 timing belt cover and the PS air hose to air intake chamber.
13. Install charcoal canister.
14. Install radiator assembly.
15. Install air cleaner, MAF meter and intake air connector pipe assembly.
(a) Connect the air cleaner case to the air duct.
(b) Connect the intake air connector to the throttle body.
(c) Install the air cleaner case with the 3 bolts.
(d) Tighten the hose clamp bolt holding the intake air connector pipe to the throttle body.
(e) Connect the PS air hose to No. 4 timing belt cover and the PCV hose to No. 2 cylinder head cover.
(f) Connect the MAF meter connector.
(g) Connect the high tension cord to the clamp on the air cleaner.
(h) Connect the high tension cord to the ignition coil.
16. Connect control cables to throttle body.
17. Install battery tray and battery.
18. Recheck engine coolant and engine oil levels.
19. Connect control cables to throttle body.
20. Fill with fuel.
21. Fill with engine oil.
22. Fill with engine coolant.
23. Start engine and check for leaks.
24. Install engine under cover.
25. Install hood. tighten mounting bolts to 13 Nm (9 ft. lbs.).
NOTE: Be careful not to damage the body or glass with the hood end.
26. Install hood and insulator.
27. Road test, check for abnormal noise, shock slippage, correct shift points and smooth operation.
28. Recheck engine coolant and engine oil levels.