Part 1

ENGINE ASSEMBLY

INSTALLATION
1. INSTALL NO.1 ENGINE MOUNTING BRACKET FRONT LH
a. Install the mounting bracket with the 4 bolts.
Torque: 36 Nm (370 kgf-cm, 27 ft. lbs.)

HINT: The LH mounting bracket is marked with an L.

2. INSTALL NO.1 ENGINE MOUNTING BRACKET FRONT RH
a. Install the mounting bracket with the 4 bolts.
Torque: 36 Nm (370 kgf-cm, 27 ft. lbs.)

HINT: The RH mounting bracket is marked with an L.

3. INSTALL ENGINE OIL LEVEL SENSOR
a. Install a new gasket to the sensor.
b. Install the sensor with the 4 bolts.
c. Connect the sensor connector.

4. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY
a. Install anew gasket and the oil filter bracket with the stud bolt and 2 nuts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
b. Connect the oil pressure switch connector.





5. INSTALL OIL PRESSURE SWITCH
a. Install the oil pressure switch.
(1) Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive: Part No.08833-00070, THREE BOND 1324 or equivalent
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)

6. INSTALL IGNITION COIL
7. INSTALL KNOCK SENSOR
8. INSTALL CRANKSHAFT POSITION SENSOR
9. INSTALL VVT SENSOR
a. Install the 2 sensors with the 2 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
b. Connect the 2 sensor connectors.





10. INSTALL CAMSHAFT POSITION SENSOR
a. Install the sensor with the bolt.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
b. Connect the 2 sensor connectors.

11. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
a. Install a new O-ring to the oil control valve.
b. Install the oil control valve with the bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)

12. INSTALL OIL FILLER CAP HOUSING
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)

13. INSTALL STARTER ASSEMBLY
14. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
a. Install a new O-ring to the water by-pass pipe.
b. Apply soapy water to the O-ring.
c. Push in the water by-pass pipe end into the pipe hole of the water pump.
d. Install the water by-pass pipe with the bolt.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
e. Install the wire clamp to the bracket of the water bypass pipe.





15. INSTALL REAR WATER BY-PASS JOINT
a. Install 2 new gaskets and the water by-pass joint with the 4 nuts. Alternately tighten the nuts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)





16. INSTALL FRONT WATER BY-PASS JOINT
a. Install 2 new gaskets and the water by-pass joint with the 4 nuts. Alternately tighten the nuts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
b. Connect the ECT sensor connector.





17. INSTALL WATER INLET HOUSING
a. Install a new O-ring to the inlet housing.
b. Apply soapy water on the O-ring.
c. Apply seal packing to the sealing groove of inlet housing as shown in the illustration.
Seal packing: Part No.08826-00100 or equivalent
Seal width: 2 to 3 mm (0.08 to 0.12 inch)

NOTICE: Remove any oil from the contact surface. Install the crankcase within 3 minutes after applying seal packing. Do not start the engine for at least 2 hours after installing.

d. Install the water inlet and housing assembly with the 2 bolts. Alternately tighten the bolts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)





18. INSTALL NO.3 TIMING BELT COVER SUB-ASSEMBLY RH
a. Install the gasket to the cover.
b. Install the cover with the cap nut and 3 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)





19. INSTALL NO.3 TIMING BELT COVER SUB-ASSEMBLY LH
a. Install the gasket to the cover.
b. Pass the camshaft position sensor wire through the cover hole.
c. Install the cover with the 4 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
d. Install the wire grommet to the cover.
e. Install the sensor connector to the sensor holder.
f. Connect the sensor connector.
g. Install the sensor wire to the wire clamp on the cover.
h. Install the engine wire to the 2 wire clamps on the cover.





i. Connect the 2 water by-pass hoses as shown in the illustration.
j. Install the No.3 water by-pass pipe to the cover with the cap nut.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)

20. INSTALL NO.2 ENGINE HANGER
a. Install the engine hanger with the 2 bolts.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)

21. INSTALL NO.1 ENGINE HANGER
a. Install the engine hanger with the 2 bolts.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)

22. INSTALL GENERATOR ASSEMBLY
23. INSTALL NO.1 IDLER PULLEY BRACKET SUB-ASSEMBLY
24. INSTALL INTAKE MANIFOLD ASSEMBLY
a. Install the manifold.

25. REMOVE ENGINE STAND
26. INSTALL NO.2 WIRING HARNESS HEAT INSULATOR
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)





27. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
a. Place a new gasket on the cylinder head with the white mark facing the manifold side.

NOTICE: Be careful of the installation direction.





b. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)

28. INSTALL NO.2 EXHAUST MANIFOLD HEAT INSULATOR
a. Install the heat insulator with the 4 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)





29. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Place a new gasket on the cylinder head with the white mark facing the manifold side.

NOTICE: Be careful of the installation direction.





b. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)

30. INSTALL NO.1 EXHAUST MANIFOLD HEAT INSULATOR
a. Install the heat insulator with the 4 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)





31. INSTALL ENGINE MOUNTING INSULATOR FRONT
a. Install the front suspension crossmember sub assembly with the 2 bolts.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)

32. INSTALL OIL LEVEL GAUGE GUIDE
a. Install a new O-ring to the guide.
b. Install the guide with the bolt.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)

33. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY

HINT: If any one of the mounting bolts is broken or deformed, replace it.





a. Apply adhesive to 2 or 3 threads of the mounting bolt end.
Adhesive: Part No.08833-00070, THREE BOND 1324 or equivalent





b. Install the front spacer, drive plate and rear spacer on the crankshaft.
c. Install and uniformly tighten the 8 mounting bolts in several passes, in the sequence shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
If any of the mounting bolts cannot meet the torque specification, replace the mounting bolt.





d. Mark the mounting bolt with paint.
e. Retighten the mounting bolt by 90° in the numerical order shown.
f. Check that the painted mark is now at a 90° angle.





34. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
a. Install the automatic transmission to the engine with the 9 bolts.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.) for 14 mm head bolt A 71 Nm (724 kgf-cm, 52 ft. lbs.) for 17 mm head bolt B

HINT: Bolt (B) is tightened to the wire harness clamp.





b. Install the 6 torque converter clutch mounting bolts.
Torque: 48 Nm (489 kgf-cm, 35 ft. lbs.)

HINT: First install the black colored bolt and then the remaining 5 bolts.





35. INSTALL FLYWHEEL HOUSING UNDER COVER
a Install the under cover with the 2 bolts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)

36. INSTALL WIRE HARNESS AND CONNECTORS
a. Connect the 2 speed sensor connectors.
b. Connect the transmission wire connector.
c. Connect the park/neutral position switch connector.





d. Install the wire harness clamps with the 5 bolts.
Torque: 71 Nm (724 kgf-cm, 52 ft. lbs.) Bolt (B)

HINT: Bolt (A) is tightened to the transmission housing.





37. INSTALL NO.1 OIL COOLER OUTLET TUBE
a. Temporarily install the oil cooler outlet tube.
b. Temporarily install the oil cooler inlet tube.
c. Install the 2 clamps with the 2 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)





d. Tighten the oil cooler outlet tube No.1.
Torque: 42 Nm (428 kgf-cm, 31 ft. lbs.)

NOTICE: Use a torque wrench with a fulcrum length of 460 mm (18.11 inch).





38. INSTALL NO.1 OIL COOLER INLET TUBE
a. Tighten the oil cooler inlet tube.
Torque: 42 Nm (428 kgf-cm, 31 ft. lbs.)

NOTICE: Use a torque wrench with a fulcrum length of 460 mm (18.11 inch).