Engine Installation

INSTALLATION





1. INSTALL GENERATOR
a Install the generator with the 2 bolts.
Torque:
52 Nm (530 kgf-cm, 38 ft. lbs.) for bolt A
21 Nm (214 kgf-cm, 16 ft. lbs.) for bolt B
b Connect the A/C wire.
c Connect the generator connector.
d Connect the generator wire with the nut, and install the cover.
Torque: 9.7 Nm (100 kgf-cm, 85 inch lbs.)





2. INSTALL PS VANE PUMP
a Install the vane pump with the 2 bolts.
Torque: 43 Nm (440 kgf-cm, 32 ft. lbs.)
b Connect the oil pressure switch connector.





3. INSTALL A/C COMPRESSOR
a Install the compressor with the 3 bolts and nut.
Torque: 24.5 Nm (250 kgf-cm, 18 ft. lbs.)
b Connect the magnetic clutch and lock sensor connector.
4. INSTALL DRIVE BELT
5. A/T: 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 Align the pin of the front spacer with the pin hole of the crankshaft, and install the front spacer.





c Install the drive plate and rear spacer as shown in the illustration.





d Install and uniformly tighten the 8 bolts in several passes, in the sequence shown.
Torque: 98 Nm (100 kgf-cm, 72 ft. lbs.)
6. M/T: INSTALL FLYWHEEL (See procure in step 5)
Torque: 130 Nm (1,326 kgf-cm, 96 ft. lbs.)
7. MT: INSTALL CLUTCH DISC AND COVER
8. INSTALL ENGINE TO TRANSAXLE





a Install the 6 upper bolts holding the transaxle to the engine.
Torque:
46 Nm (470 kgf-cm, 34 ft. lbs.) for bolt A
64 Nm (650 kgf-cm, 47 ft. lbs.) for bolt B





b A/T: Connect the connectors and clamps.
1 Connect the park/neutral position switch connector.
2 Connect the solenoid wire connector.
3 Connect the input turbine speed sensor connector.
4 Connect the counter gear speed sensor connector.
5 Connect the vehicle speed sensor.
6 Connect the wire clamp from the bracket.
7 Connect the wire clamp to the engine mounting bracket.





c M/T: Connect the connectors.
1 Connect the vehicle speed sensor connector.
2 Connect the back-up light switch connector.





d Install the 4 lower bolts holding the engine to the transaxle.
Torque: 44 Nm (450 kgf-cm, 32 ft. lbs.)





9. A/T: INSTALL TORQUE CONVERTER CLUTCH BOLTS
a Apply adhesive to 2 or 3 threads of the bolt end.
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 Nm (418 kgf-cm, 30 ft. lbs.)

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





10. 2WD: INSTALL CENTER BEARING BRACKET
Install the bearing bracket with the 3 bolts.
Torque: 34 Nm (347 kgf-cm, 25 ft. lbs.)





11. 4WD: INSTALL STIFFENER PLATE
Install the stiffener plate with the 5 bolts.
Torque: 34 Nm (347 kgf-cm, 25 ft. lbs.)
12. INSTALL ENGINE AND TRANSAXLE ASSEMBLY TO FRONT SUSPENSION CROSSMEMBER AND CENTER ENGINE MOUNTING MEMBER





a Attach the engine and transaxle assembly to the suspension crossmember and engine mounting member.
b Install the bolt holding the rear engine mounting bracket to the mounting insulator.
Torque: 88 Nm (898 kgf-cm, 65 ft. lbs.)





c Install the bolt holding the front engine mounting bracket to the mounting insulator.
Torque: 56 Nm (571 kgf-cm, 41 ft. lbs.)
13. INSTALL ENGINE, TRANSAXLE, FRONT SUSPENSION CROSSMEMBER AND CENTER ENGINE MOUNTING MEMBER ASSEMBLY IN VEHICLE





a Attach the engine sling device to the engine hangers.
b Lift the engine into the engine compartment.





c Install the bolt and 2 nuts holding the RH engine mounting insulator to the timing chain cover.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)





d Install the bolt holding the LH engine mounting bracket to the mounting insulator.
Torque: 56 Nm (571 kgf-cm, 41 ft. lbs.)





e Support the suspension crossmember with a jack.
f Install the 6 bolts holding the suspension crossmember engine mounting member to the body.
Torque:
39 Nm (400 kgf-cm, 28 ft. lbs.) for bolt A
113 Nm (1,150 kgf-cm, 82 ft. lbs.) for bolt B
157 Nm (1,600 kgf-cm, 115 ft. lbs.) for bolt C





14. INSTALL PS GEAR ASSEMBLY
Install the PS gear assembly with the 2 bolts.
Torque: 137 Nm (1,400 kgf-cm, 101 ft. lbs.)
15. REMOVE NO. 1 AND NO. 2 ENGINE HANGERS





16. CONNECT STABILIZER BAR LINKS
Connect the LH and RH stabilizer links with the 2 nuts.
Torque: 44 Nm (450 kgf-cm, 32 ft. lbs.)





17. INSTALL FRONT EXHAUST PIPE
Install 2 new gaskets and the exhaust pipe, with the 2 compression rings and 4 bolts.
Torque:
43 Nm (439 kgf-cm, 32 ft. lbs.) for bolt A
49 Nm (500 kgf-cm, 36 ft. lbs.) for bolt B
18. INSTALL LH AND RH FRONT DRIVE SHAFTS
19. 4WD: INSTALL PROPELLER SHAFT
20. CONNECT GROUND CABLE TO TRANSAXLE
Torque: 19 Nm (195 kgf-cm, 14 ft. lbs.)





21. A/T: CONNECT OIL COOLER HOSES





22. A/T: CONNECT SHIFT CONTROL CABLE TO TRANSAXLE
a Connect the control cable with the nut.
Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.)
b Connect the control cable with the clip.
c Connect the control cable to the cable clamp.





23. M/T: INSTALL CLUTCH RELEASE CYLINDER AND TUBE
a Install the release cylinder with the 5 bolts.
Torque:
25 Nm (255 kgf-cm, 18 ft. lbs.) for bolt A
12 Nm (120 kgf-cm, 9 ft. lbs.) for bolt B
5 Nm (51 kgf-cm, 44 inch lbs.) for bolt C
b Install the heat insulator with the 2 bolts.
Torque: 12 Nm (120 kgf-cm, 44 ft. lbs.)





24. INSTALL STARTER
a Install the starter.
b Connect the starter cable with the nut.
Torque: 8.8 Nm (86 kgf-cm, 78 inch lbs.)
c Install the starter with the 2 bolts.
Torque: 37 Nm (378 kgf-cm, 28 ft. lbs.)
d Connect the connector.
e Connect the hose to the dipstick guide.





25. M/T: CONNECT SHIFT CONTROL CABLES TO TRANSAXLE
a Connect the 2 control cables with the 2 clips.
b Install the 2 washers and 2 clips.
26. DISCONNECT TUBES, HOSES, CONNECTOR, CABLE AND WIRE





a Install 2 new O-rings, and connect the discharge and liquid tubes to the compressor.
b Connect the accelerator cable.
c Connect the ground wire to the cylinder head.





d Install a new gasket, and connect the suction hose and pressure feed tube to the PS vane pump.
e Connect the upper radiator hose.
f Connect the lower radiator hose.
g Connect the fuel tube connector.
h Connect the 2 heater hoses.





i Connect the connector to the fusible link block.
27. CONNECT ENGINE WIRE TO CABIN
a Push in engine wire through the cabin.
b Connect the 6 engine wire connectors to the ECM and instrument panel wire.
c Install the glove compartment door with the 2 screws.





28. INSTALL ENGINE ROOM J/B
a Connect the engine wire clamp.
b Connect the connector.
c Push into the engine wire connector.
d Install the engine room J/B, and tighten the bolt until it fails to catch.
e Install the engine room J/B cover.





29. INSTALL AIR CLEANER ASSEMBLY
a Connect the air cleaner hose to the throttle body, and install the air cleaner assembly with the 3 bolts.
b Connect the MAF meter connector.
c Connect the 2 EVAP hoses to the VSV.
d Connect the VSV connector for EVAP.
e Connect the CCV hose to the air cleaner.
f Connect the PCV hose to the cylinder head cover.





30. INSTALL BATTERY AND TRAY
a Install the bakery bracket with the 5 bolts.
b Install the battery tray and battery with the hold down clamp.
c Install the cowl top ventilation louver
31. INSTALL RADIATOR RESERVOIR TANK
32. INSTALL HOOD
33. FILL WITH ENGINE COOLANT
34. FILL WITH ENGINE OIL
35. FILL WITH TRANSFER OIL
36. FILL WITH TRANSAXLE OIL
37. START ENGINE AND CHECK FOR LEAKS
38. BLEED POWER STEERING SYSTEM
39. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
40. RECHECK ENGINE COOLANT AND OIL LEVELS
41. INSTALL ENGINE UNDER COVERS