Engine Installation
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INSTALLATION
1. INSTALL FLYWHEEL
HINT:
^ The mounting bolts are tightened in steps c. and e.
^ If any one of the mounting bolts is broken or deformed, replace it.
a. Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
b. Install the flywheel on the crankshaft.
c. Install and uniformly tighten the 8 bolts in several passes, in the sequence shown.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
If any one of the bolts does not meet the torque specification, replace the bolt.
d. Mark the flywheel bolt with paint.
e. Retighten the flywheel bolts by an additional 90°.
2. INSTALL CLUTCH DISC AND COVER
3. INSTALL TRANSAXLE TO ENGINE
a. Attach the transaxle to the engine, and install the 6 bolts.
b. Install the starter.
4. SET ENGINE JACK
NOTICE: Using a chain, hold the engine tightly.
5. INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN VEHICLE
a. Raise the engine into the engine compartment.
b. M/T: Temporarily install the rear suspension member to the engine with the through bolt and nut.
c. SMT: Temporarily install the rear suspension member and HPU assembly to the engine with the through bolt and nut.
d. Connect the rear suspension member with the 4 bolts.
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)
e. Connect the ABS wire with the 2 bolts.
f. Install the RH engine mounting insulator with the 3 bolts and 3 nuts.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)
g. Temporarily install the through bolt and nut holding the LH engine mounting insulator to the mounting bracket.
h. Tighten the through bolt and nut holding the rear engine mounting insulator to the mounting bracket.
Torque: 93 Nm (948 kgf-cm, 69 ft. lbs.)
NOTICE: Be sure to tighten the bolt at the upper end of slot.
i. Install the through bolt holding the front engine mounting insulator to the mounting bracket.
Torque: 93 Nm (950 kgf-cm, 69 ft. lbs.)
j. Tighten the through bolt and nut holding the LH engine mounting insulator to the mounting bracket.
Torque: 87 Nm (887 kgf-cm, 64 ft. lbs.)
k. Remove the engine jack, and install the No. 2 cylinder head cover with the 2 clips and 2 nuts.
6. INSTALL DRIVE SHAFTS
7. M/T: CONNECT TRANSAXLE CONTROL CABLES
8. M/T: CONNECT CLUTCH HOSE
9. CONNECT FUEL TUBE
Connect the fuel tube to the fuel pipe, and install the fuel pipe clamp.
10. CONNECT HPU CONNECTOR AND SET SYSTEM HOSES
11. CONNECT WATER HOSES
Connect the 2 radiator hoses and 2 heater hoses.
12. CONNECT ENGINE WIRE
a. Connect the 3 wire brackets and heated oxygen sensor (bank 1 sensor 2) wire to the vehicle.
b. Assemble the positive (+) battery wires.
1) Assemble the battery wires, and install the terminal with the nut.
2) Install the terminal cover.
c. Connect the 2 ground wires with the 2 bolts.
d. Connect the engine wire to the J/B No. 1.
1) Connect the engine wire with the nut.
2) Install the relay box cover.
e. SMT: Connect the transmission control ECU connector.
f. Connect the engine wire to the luggage compartment.
1) Pull in the engine wire to the luggage compartment, and connect the grommet.
2) Connect the 4 junction connectors.
3) Connect the 2 ECM connectors.
4) Install the luggage compartment box.
13. INSTALL A/C COMPRESSOR
a. Install the A/C compressor with the 3 bolts.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
b. Connect the A/C compressor connector.
c. Install the drive belt.
14. INSTALL FRONT EXHAUST PIPE
a. Connect the ring.
b. Install 3 new gaskets and the front exhaust pipe with the 2 bolts, 2 springs and 3 nuts.
Torque:
43 Nm (438 kgf-cm, 32 ft. lbs.) for bolt
62 Nm (632 kgf-cm, 46 ft. lbs.) for nut
c. Connect the heated oxygen sensor (bank 2 sensor 1) connector.
15. INSTALL REAR BUMPER COVER AND REAR COMBINATION LIGHTS
16. CONNECT ACCELERATOR CABLE
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)
17. INSTALL INTAKE AIR HOSE AND AIR CLEANER CAP ASSEMBLY
a. Install the air cleaner lower case with the 2 bolts.
b. Install the air filter.
c. Install the intake air hose and air cleaner cap assembly to the throttle body, and tighten the hose clamp.
d. Connect the air cleaner cap with the 2 clamps.
e. Connect the 4 hoses.
f. Connect the MAF meter connector.
g. Connect the VSV connector for EVAP.
h. Connect the VSV connector for CCV.
18. INSTALL BATTERY BRACKET
a. Install the battery bracket with the 3 bolts.
HINT: Install bolt A with the air cleaner case.
b. Install the tray and battery.
19. M/T: FILL CLUTCH RESERVOIR WITH BRAKE FLUID AND BLEED CLUTCH SYSTEM
20. M/T: FILL WITH TRANSAXLE OIL
21. SMT: FILL WITH TRANSMISSION OIL
22. FILL WITH ENGINE OIL
23. SMT: CHECK SMT SYSTEM FLUID LEVEL
24. FILL WITH ENGINE COOLANT
25. SMT: START ENGINE AND PERFORM INITIAL LEANING OF SMT SYSTEM
26. CHECK FOR LEAKS
27. PERFORM ENGINE ADJUSTMENT
28. CHECK FRONT WHEEL ALIGNMENT
29. INSTALL ENGINE UNDER COVERS
30. INSTALL SUSPENSION UPPER BRACE
31. INSTALL ENGINE HOOD
32. ROAD TEST VEHICLE
Check for abnormal noises, shock slippage, correct shift points and smooth operation.
33. RECHECK ENGINE COOLANT AND OIL LEVELS