Installation

INSTALLATION OF ENGINE
1. ASSEMBLE ENGINE AND TRANSAXLE
M/T
A/T
2. (A/T)
INSTALL STARTER

3. INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN VEHICLE
(a) Attach the engine chain hoist to the engine hangers.
(b) Lower the engine into the engine compartment.
Tilt the transaxle downward, lower the engine and clear the LH mounting.

NOTICE: Be careful not to hit the PS gear housing or neutral start switch (A/T).

(d) Attach the RH mounting insulator to the mounting bracket and body, and temporarily install the through bolt and two nuts.

(e) Install the LH mounting bracket to the transaxle case with the three bolts
Torque: 52 N.m (530 kgf.cm, 38 ft.lbf)

(f) Attach the LH mounting insulator to the mounting bracket and body with the through bolt and four bolts. Torque the bolts.
Torque:
Bolt 63 N.m (650 kgf.cm, 47 ft.lbf)
Through bolt 87 N.m (890 kgf.cm, 64 ft.lbf)
(g) Torque the through bolt and two nuts of the RH mounting insulator.
Torque:
Nut 52 N.m (530 kgf.cm, 38 ft.lbf)
Through bolt 87 N.m (890 kgf.cm, 64 ft.lbf)
(h) Remove the engine chain hoist from the engine.

4. INSTALL RH ENGINE MOUNTING STAY
Install the mounting stay with the bolt and nut.
Torque: 73 N.m (740 kgf.cm, 54 ft.lbf)
5. CONNECT GROUND CONNECTOR TO GROUND WIRE ON RH FENDER APRON

6. INSTALL LH ENGINE MOUNTING STAY (M/T)
(a) Install the mounting stay with the two nuts.
(b) Connect the ground strap.
Torque: 21 N.m (210 kgf.cm, 15 ft.lbf)

(A/T
(a) Install the mounting stay with the bolt and nut.
Torque: 21 N.m (210 kgf.cm, 15 ft.lbf)
b) Connect the ground strap to the transaxle with the bolt.

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

8. INSTALL REAR ENGINE MOUNTING BRACKET AND INSULATOR
(a) Install the mounting bracket with the three bolts.
Torque: 77 N.m (790 kgf.cm, 57 ft.lbf)
(b) Temporarily install the mounting insulator with the through bolt.

9. INSTALL ENGINE MOUNTING CENTER MEMBER
(a) Install the engine mounting center member with the four bolts.
Torque: 52 N.m (530 kgf.cm, 38 ft.lbf)
(b) Install and torque the four bolts holding the insulators to the center member.
Torque: 73 N.m (740 kgf.cm, 54 ft.lbf)

10. TIGHTEN FRONT AND REAR ENGINE MOUNTING THROUGH BOLTS
(a) Tighten the rear through bolt.
Torque: 87 N.m (890 kgf.cm, 64 ft.lbf)

(b) Tighten the front through bolt.
Torque: 87 N.m (890 kgf.cm, 64 ft.lbf)

11. INSTALL PS PUMP
(a) Install the PS pump with the four bolts.
Torque:
Adjusting bolt 39 N.m (400 kgf.cm, 29 ft.lbf)
Others 43 N.m (440 kgf.cm, 32 ft.lbf)
(b) Install the drive belt.
(c) Connect the two air hoses to the air pipe.

12. (w/A/C)
INSTALL A/C COMPRESSOR
(a) Install the compressor with the three bolts.
Torque: 27 N.m (280 kgf.cm; 20 ft.lbf)
(b) Connect the two connectors.
(c) Connect the A/C compressor connector.
13. INSTALL DRIVE SHAFTS

14. (A/T
INSTALL TRANSAXLE CONTROL CABLE TO ENGINE MOUNTING CENTER MEMBER
Install the control cable with the two clamps and bolts.

15. INSTALL FRONT EXHAUST PIPE
(a) Install the support hook on the front exhaust pipe to the support bracket.
(b) Place two new gaskets on the front and rear of the front exhaust pipe.
(c) Temporarily install the two bolts and new nuts holding the exhaust pipe to the center exhaust pipe.
(d) Using a 14 mm deep socket wrench, install the three new nuts holding the exhaust pipe to the catalytic converter.
Torque: 62 N.m (630 kgf.cm, 46 ft.lbf)
(e) Tighten the two bolts and nuts holding the exhaust pipe to the center exhaust pipe.
Torque: 43 N.m (440 kgf.cm, 32 ft.lbf)
(f) Install the clamp with the bolt.

16. INSTALL SUSPENSION LOWER CROSSMEMBER
Install the lower crossmember with the four bolts and two nuts.
Torque: 152 N.m (1,550 kgf.cm, 112 ft.lbf)

17. CONNECT ENGINE WIRE TO CABIN
(a) Push in the engine wire through the cowl panel. Install the two nuts.

(b) Connect the following connectors:
(1) Two engine (& ECT) ECU connectors
(2) Two cowl wire connectors
(3) A/C amplifier connector
18. CONNECT ENGINE WIRE
(a) Engine wire clamp to wire bracket on RH fender apron
(b) Two cowl wire connectors

19. CONNECT VACUUM HOSES
(a) Vacuum sensor hose to gas filter
(b) Brake booster vacuum hose to intake manifold
(c) (W/ Cruise Control System (w/o ABS) Actuator vacuum hose to intake manifold

20. CONNECT TRANSAXLE CONTROL CABLE(S) TO TRANSAXLE

21. (M/T)
INSTALL CLUTCH RELEASE CYLINDER
Install the release cylinder and tube with the four bolts.
22. (M/T)
INSTALL STARTER

23. CONNECT FUEL HOSES
Torque (Union bolt): 29 N.m (300 kgf.cm, 22 ft.lbf)

24. CONNECT SPEEDOMETER CABLE
25. CONNECT HEATER HOSES

26. INSTALL CHARCOAL CANISTER
(a) Install the charcoal canister with the two bolts.
(b) Connect the three hoses.

27. INSTALL ENGINE WIRE BRACKET
(a) Install the wire bracket with the two bolts. Install the noise filter.
(b) Install the wire clamp to the wire bracket.
28. CONNECT WIRES AND CONNECTORS
(a) Check connector
(b) Igniter connector
(c) Vacuum sensor connector
(d) Ground straps from LH fender apron

29. INSTALL SUSPENSION UPPER BRACE
(a) Install the suspension upper brace with the two bolts and four nuts.
Torque: Bolt 21 N.m (210 kgf.cm, 15 ft.lbf)
Nut 64 N.m (650 kgf.cm, 47 ft.lbf)
(b) Install the outside lower windshield moulding.
(c) Install the two wiper arms.

30. INSTALL RADIATOR RESERVOIR TANK
Install the reservoir tank with the two nuts.

31. INSTALL RADIATOR

32. (w/ CRUISE CONTROL SYSTEM (w/ ABS)) INSTALL CRUISE CONTROL ACTUATOR BRACKET
(a) Install the actuator bracket with the two bolts and nut.
(b) Install the actuator connector to the bracket.

33. (w/ CRUISE CONTROL SYSTEM
INSTALL CRUISE CONTROL ACTUATOR BRACKET
(w/ ABS)
(a) Install the actuator with the four bolts.
(b) Connect the actuator connector.

(w/o ABS)
(a) Install the actuator with the three bolts.
(b) Connect the cable to the actuator.
(c) Connect the actuator connector.
(d) Connect the actuator vacuum hose.
(e) install the actuator cover.
34. INSTALL BATTERY

35. INSTALL A/C RELAY BOX

36. CONNECT ENGINE WIRE~ AND INSTALL ENGINE RELAY BOX
(a) Connect the fusible link cassette and two connectors of the engine wire to the relay box.
(b) Install the lower cover to the relay box.

38. INSTALL AIR CLEANER ASSEMBLY
(a) Install the air cleaner case with the three bolts.
(b) Install the air cleaner element.
(c) Connect the air cleaner hose to the throttle body.
(d) Install the air cleaner cap.
(e) Connect the intake air temperature sensor connector.
39. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY
40. FILL WITH ENGINE COOLANT
Capacity (w/ Heater):
M/T 6.2 liters (6.6 US qts, 5.5 imp. qts)
A/T 6.1 liters (6.4 US qts, 5.4 imp. qts)
41. FILL WITH ENGINE OIL
Capacity (w/ Oil cooler):
Drain and refill
W/ Oil filter change 4.2 liters (4.4 US qts, 3.7 imp. qts)
W/O Oil filter change 3.8 liters (4.0 US qts, 3.3 imp. qts)
Dry fill 4.6 liters (4.9 US qts, 4.0 imp. qts)
Capacity (w/o Oil cooler):
Drain and refill
W/ Oil filter change 4.1 liters (4.3 US qts, 3.6 imp. qts)
W/O Oil filter change 3.7 liters (3.9 US qts, 3.3 imp. qts)
Dry fill 4.5 liters (4.8 US qts, 4.0 imp. qts)
42. START ENGINE AND CHECK FOR LEAKS
43. PERFORM ENGINE ADJUSTMENT
(a) Adjust the alternator drive belt.
Drive belt tension:
W/ A/C
New belt 165 ± 10 lbf
Used belt 110 ± 10 lbf
W/O A/C
New belt 125 ± 25 lbf
Used belt 95 ± 20 lbf
(b) Adjust the PS drive belt.
Drive belt tension:
New belt 125 ± 25 lbf
Used belt 80 ± 20 lbf
(c) Adjust the ignition timing.
Ignition timing: 10° BTDC at idle (w/ Terminals TE1 and E1 connected)
44. INSTALL ENGINE UNDER COVERS
45. INSTALL HOOD
46. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
47. RECHECK ENGINE COOLANT AND ENGINE OIL LEVELS