Installation

INSTALLATION

1. Assemble engine and transaxle M/T.

2. A/T Install engine and transaxle assembly in vehicle.
(a) Attach the engine hoist chain to the engine hangers.
(b) Lower the engine into the engine compartment. Tilt the transaxle downward, lower the engine and clear the LH mounting.

CAUTION: Be careful not to hit the P/S gear housing or neutral start switch.

(2WD)
(d) Align the RH mounting insulator into the bracket, and temporarily install the through bolt and nut.
(e) Temporarily install the mounting stay bolt (A).

(f) (4WD)
- Attach the RH mounting insulator to the mounting bracket and body, and temporarily install the through bolt and two nuts.

Torque:
Bolt: 530 kg-cm (38 ft-lb, 52 Nm)
Through Bolt: 890 kg-cm (64 ft-lb, 87 Nm)

(g) (2WD)
Torque the bolt and four nuts of the RH mounting insulator. Do not torque the bolt (A) yet.
Torque:
Nut To bracket 530 kg-cm (38 ft-lb, 52 N.m)
To body 900 kg-cm (65 ft-lb, 88 N.m)
Bolt 650 kg-cm (47 ft-lb, 64 N.m)
(h) (4WD)
Torque the through bolt and two nuts of the RH mounting insulator
Torque:
Nut 530 kg-cm (38 ft-lb, 52 N.m)
Through bolt 890 kg-cm (64 ft-lb, 87 N.m)
(i) Remove the engine hoist chain from the engine

3. INSTALL ENGINE RH MOUNTING STAY
(2WD)
Install the mounting stay with the three bolts. Torque the bolts.
Torque: 740 kg-cm (54 ft-lb. 73 N.m)

(4WD)
Install the mounting stay with the bolt and nut. Torque the bolt and nut.
Torque: 740 kg-cm (54 ft-lb, 73 N.m)

4. (A/T)
INSTALL ENGINE LH MOUNTING STAY (2WD)
Install the mounting stay with the bolt and nut. Torque the bolt and nut.
Torque: 210 kg-cm (15 ft-lb, 21 N.m)

(4WD)
Install the mounting stay with the two nuts.
Torque: 210 kg-cm (15 ft-lb, 21 N.m)

5. INSTALL PS OIL RESERVOIR TANK
Install the two bolts.
6. CONNECT ENGINE WIRE
(a) Push in the engine wire through the cowl panel.
(b) Connect the following connectors.
(1) Three TCCS ECU connectors
(2) Circuit opening relay connector
(3) Cowl wire connector
(4) Instrument panel wire connect9r
(c) Install the glove compartment box.

7. RAISE VEHICLE

NOTICE: Be sure the vehicle is securely supported.

8. INSTALL ENGINE FRONT MOUNTING BRACKET AND INSULATOR
a) Install the mounting bracket with the two bolts. Torque the bolts.
Torque: 790 kg-cm (57 ft-lb, 77 N.m)
b) Temporarily install the mounting insulator with the through bolt and nut.

9. (2WD)
INSTALL ENGINE CENTER MOUNTING BRACKET AND INSULATOR ASSEMBLY
Install the mounting bracket and insulator assembly with the two bolts. Torque the bolts.
Torque: 490 kg-cm (35 ft-lb, 48 N.m)
(a) Install the LH mounting bracket onto the transaxle case with the three bolts.
(b) Install the LH mounting insulator onto the bracket with the three bolts. Align the LH mounting insulator into the body bracket, and temporarily install the mounting insulator through bolt.
(c) Remove the engine hoist chain from the engine.
10. Connect TCCS ECU connectors.
11. Raise vehicle.

CAUTION: Be sure the vehicle is securely supported.

12. Install engine mounting center member.

(a) Install the engine mounting center member with the four bolts. Torque the bolts.
Torque: 400 kg-cm (29 ft-lb, 39 Nm)
(b) Install the front and rear engine mounting insulators with the four nuts and two nuts. Torque the bolts and nuts.
Torque: 440 kg-cm (32 ft-lb, 43 Nm)

13. Connect exhaust pipe to catalyst converter
(a) Place a new gasket on the exhaust pipe.
(b) Connect the exhaust pipe with new three nuts. Torque the nuts.
Torque: 630 kg-cm (46 ft-lb, 62 Nm)

16. Install suspension lower crossmember. Torque the bolts.
Torque:
(A) 2,110 kg-cm (153 ft-lb, 206 Nm)
(B) 400 kg-cm (29 ft-lb, 39 Nm)
17. Install engine under covers.
18. Torque bolts of engine LH and RH mounting insulators.
Torque: 800 kg-cm (58 ft-lb, 78 Nm)
19. Connect vacuum hoses, wires and connectors
(a) Check connector
(b) Ground straps from LH fender apron
(c) Connector from relay box
(d) Solenoid resistor connector
(e) Brake booster vacuum hose
(f) A/C idle-up vacuum hoses
(9) Charcoal canister vacuum hose
20. Install A/C compressor.
21. Connect transaxle control cable.

22. (M/T) Install clutch release cylinder and tube clamp
23. Connect speedometer cable.
24. Connect fuel hoses.
(a) Fuel inlet hose
(b) Fuel return hose
25. Connect heater hoses.
26. Install igniter.

27. Install air cleaner assembly, air flow meter and air cleaner hose.
(a) Install the air cleaner case with the three bolts.
(b) Install the air cleaner element.
(c) Connect the air cleaner hose, and install the air cleaner cap and air flow meter with the four clips.
(d) Connect the air flow meter connector.
28. Connect ground strap to alternator upper bracket.

29. Install cruise control actuator and bracket.
(a) Install the actuator and bracket.
(b) Connect the actuator connector.
(c) Connect the actuator vacuum hoses.
30. (A/T) Install throttle cable, and adjust it.
31. Install accelerator cable, and adjust it.
32. Install radiator.
33. Install battery.
34. Fill with engine coolant
capacity (w/ heater):
6.4 liters (6.8 US qts, 5.6 Imp. qts)
35. Fill with engine oil
Capacity:
Drain and refill
w/o oil filter change
143.7 liters (3.9 US qts, 3.3 Imp. qts)
w/ Oil filter change
4.1 liters (4.3 US qts, 3.6 Imp. qts)
Dry fill 4.5 liters (4.8 US qts, 4.0 Imp. qts)
36. Start engine and check for leaks
37. Perform engine adjustment
(a) Adjust the drive belt.
Drive belt tension:
Alternator
w/ Air con. New belt 175 +/- 5 lb
Used belt 13O +/- 1O lb
w/o Air con. New belt 125 +/- 25 lb
Used belt 95 +/- 20 lb
P/S pump 125 +/- 1O lb
Used belt 80 +/- 20 lb
(b) Adjust the ignition timing.
Ignition timing: 10 ° BTDC @ idle (w/ Terminals T and E1 short-circuited)
(c) Adjust the valve clearance.
Valve clearance:
Intake 0.19-0.29 mm (0.007-0.011 in.)
Exhaust 0.28-0.38 mm (0.011 -0.015 in.)
38. Install hood.
39. Check toe-in.
40. Perform road test.
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
41. Recheck engine coolant and engine oil levels.