Installation

INSTALLATION OF ENGINE
1. ASSEMBLE ENGINE AND TRANSAXLE M/T/A/T
2. 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: 530 kg-cm (38 ft-lb, 52 N.m)

(f) Attach the LH mounting insulator to the mounting bracket and body with the through bolt and three bolts. Torque the bolts.
Torque:
Bolt 490 kg-cm (35 ft-lb, 48 N.m)
Through bolt 890 kg-cm (64 ft-lb, 87 N.m)
(g) Torque the two nuts, bolt and through bolt of the RH mounting insulator.
Torque:
Nut 530 kg-cm (38 ft-lb, 52 N.m)
Bolt 650 kg-cm (47 ft-lb, 64 N.m)
Through bolt 890 kg-cm (64 ft-lb, 87 N.m)
(h) Remove the engine chain hoist from the engine.

4. INSTALL RH ENGINE MOUNTING STAY
Install the mounting stay with the three bolts.
Torque: 430 kg-cm (31 ft-lb, 42 N.m)
5. INSTALL CONNECTOR TO GROUND WIRE ON RH FENDER APRON

6. INSTALL LH ENGINE MOUNTING STAY
Install the mounting stay with the bolt and nut. Connect the ground strap
Torque: 210 kg-cm (15 ft-lb, 21 N.m)
7. CONNECT GROUND WIRE TO TRANSAXLE

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

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

10. INSTALL ENGINE MOUNTING CENTER MEMBER
(a) Install the engine mounting center member with the four bolts.
Torque: 530 kg-cm (38 ft-lb, 52 N.m)
(b) Install and torque the four bolts holding the insulators to the center member.
Torque: 650 kg-cm (47 ft-lb, 64 N.m)

11. TIGHTEN FRONT AND REAR ENGINE MOUNTING THROUGH BOLTS
Torque: 890 kg-cm (64 ft-lb, 87 N.m)

12. INSTALL PS PUMP
(a) Install the PS pump with the two bolts.
Torque: 400 kg-cm (29 ft-lb, 39 N.m
(b) Install the drive belt.
(c) Connect the air hose to the air pipe.
(d) Connect the air hose to the air intake chamber.

13. (w/A/C)
INSTALL A/C COMPRESSOR
(a) Install the compressor with the four bolts.
Torque: 250 kg-cm (18 ft-lb, 25 N.m)
(b) Connect the two connectors.
(c) Connect the A/C compressor connector.

14. CONNECT HEATER HOSE TO WATER INLET PIPE
15. INSTALL DRIVE SHAFTS

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

17. INSTALL FRONT EXHAUST PIPE
(a) Install the support hook on the front exhaust pipe to the support bracket.
(b) Place two (CALIF.) or three (others) new gaskets on the front and rear of the front exhaust pipe.
(c) Temporarily install the two bolts and new nuts holding the front exhaust pipe to the catalytic converter.
(d) Using a 14 mm deep socket wrench, install the two CALIF.) or three (others) new nuts holding the front exhaust pipe to the exhaust manifold.
Torque: 630 kg-cm (46 ft-lb, 62 N.m)
(e) Tighten the two bolts and nuts holding the front exhaust pipe to the catalytic converter.
Torque: 440 kg-cm (32 ft-lb, 43 N.m)
(f) Install the clamp with the bolt.
(g) Connect the oxygen sensor connector.

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

19. 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) Engine ECU connector
(2) Two cowl wire connectors
(3) A/C amplifier connector
(4) O/D diode connector
20. CONNECT ENGINE WIRE
(a) Engine wire clamp to wire bracket on RH fender apron
(b) Two cowl wire connectors

21. CONNECT VACUUM HOSES
(a) Vacuum sensor hose to gas filter on air intake chamber
(b) Brake booster vacuum hose to air intake chamber
(c) Three A/C idle-up vacuum hoses to ASV on air intake chamber
(d) A/C vacuum hose to air pipe

22. CONNECT TRANSAXLE CONTROL CABLE(S) TO TRANSAXLE

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

24. CONNECT FUEL HOSES
Torque (Union bolt): 300 kg-cm (22 ft-lb, 29 N.m)

25. CONNECT SPEEDOMETER CABLE
26. CONNECT HEATER HOSE TO WATER INLET

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

28. 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.
29. CONNECT WIRES AND CONNECTORS
(a) Check connector
(b) Vacuum sensor connector
(c) Ground straps from LH fender apron

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

33. INSTALL A/C RELAY BOX

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

36. 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) Connect the air hose to the air pipe.
(e) Install the air cleaner cap.
(f) Connect the intake air temperature sensor connector
37. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY
38. FILL WITH ENGINE COOLANT
M/T 5.2 liters (5.5 US qts, 4.6 Imp. qts)
A/T 5.5 liters (5.8 US qts, 4.8 Imp. qts)
39. FILL WITH ENGINE OIL
Capacity:
Drain and refill
W/Oil filter change 3.2 liters (3.3 US qts, 2.8 Imp. qts)
W/o Oil filter change 3.0 liters (3.1 US qts, 2.6 Imp. qts)
Dry fill 3.7 liters (3.9 US qts, 3.3 Imp. qts)
40. START ENGINE AND CHECK FOR LEAKS
41. PERFORM ENGINE ADJUSTMENT
(a) Adjust the alternator drive belt.
Drive belt tension: New belt 160 ± 20 lb
Used belt 130 ± 20 lb
(b) Adjust the PS drive belt.
Drive belt tension: New belt 125 ± 25 lb
Used belt 80 ± 20 lb
(c) Adjust the A/C drive belt.
Drive belt tension: New belt 160 ± 25 lb
Used belt 100 ± 20 lb
(d) Adjust the ignition timing.
Ignition timing: 10° BTDC at idle
(w/ Terminals TE1 and E1 connected)
42. INSTALL ENGINE UNDER COVERS
43. INSTALL HOOD
44. PERFORM ROAD TEST
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
45. RECHECK ENGINE COOLANT AND ENGINE OIL LEVELS