Installation
1. Install engine and transmission assembly in vehicle as follows:
(a) Attach the engine hoist chain to the engine hangers.
(b) Lower the engine and transmission assembly into the engine compartment.
NOTE: Install the engine and transmission assembly carefully without damaging the A/C compressor and cooling fan.
(c) Insert the stud bolts of the front engine mounting insulators into the stud bolt holes of the front suspension crossmember.
(d) Install the 2 nuts holding the engine front mounting insulators to the front suspension crossmember hand tight.
(e) Keep the engine level with a jack.
(f) Remove the hoist chain.
(g) Install the support member to the engine rear mounting insulator with the 4 nuts with the front mark facing forward hand tight.
(h) Install the 4 bolts holding the support member to the body.
Torque: 25 Nm (260 kg.cm, 19 ft.lb).
(i) Tighten the 4 nuts holding the support member to the engine rear mounting insulator.
Torque: 13 Nm (135 kg.cm, 10 ft.lb).
(j) Tighten the 2 nuts holding the engine front mounting insulators to the front suspension crossmember.
Torque: 74 Nm (750 kg.cm, 54 ft.lb).
(k) Install the hole plugs.
2. Install propeller shaft, refer to Transmission and Drivetrain.
3. Connect transmission control rod as follows:
(a) Shift the shift lever to N position.
(b) Fully turn the control shaft lever back and return 2 notches. It is now in neutral position.
(c) Connect the control rod to the shift lever with the nut.
Torque: 13 Nm (130 kg.cm, 9 ft.lb).
4. Install rear center floor crossmember brace.
Torque: 13 Nm (130 kg.cm, 9 ft.lb).
5. Install the exhaust pipe heat insulator with the 6 bolts with the front mark facing forward.
6. Install No.2 front exhaust pipe with 2 new gaskets and 4 new nuts.
Torque: 62 Nm (630 kg.cm, 46 ft.lb).
7. Install exhaust pipe assembly as follows:
(a) Install the 2 hooks of the tailpipes to the 4 rings on the tailpipe brackets.
(b) Install the 2 hooks of the exhaust pipe to the rings on the exhaust pipe brackets.
(c) Install the pipe support bracket with the 2 bolts.
Torque: 43 Nm (440 kg.cm, 32 ft.lb).
(d) Install a new gasket and the No.2 front exhaust pipe to the front exhaust pipe with the 2 bolts and nuts.
Torque: 43 Nm (440 kg.cm, 32 ft.lb).
8. Install heated oxygen sensor as follows:
(a) Install the oxygen sensor to the front exhaust pipe.
Torque: 44 Nm (450 kg.cm, 33 ft.lb).
NOTE:
- Before installing the oxygen sensor, twist the sensor wire counterclockwise 3 and a 1/2 turns.
- After installing the oxygen sensor, check that the sensor wire is not twisted. If it is twisted, remove the oxygen sensor and reinstall it.
(b) Install the sensor cover with the 2 bolts.
(c) Connect the wire grommet to the floor.
9. Connect engine wire to cabin as follows:
(a) Push in the engine wire through the cowl panel.
NOTE: Be careful not to damage the engine wire.
(b) Connect the connector to the cowl wire connector.
(c) Connect the connector to the Engine Control Module (ECM).
(d) Install the ECM with the nut.
(e) Install the ECM protector with the bolt and 2 nuts.
(f) Install the floor carpet.
(g) Install the air heater guide.
(h) Install the instrument panel under cover, as follows:
- Install the step light to the under cover.
- Install the under cover with the 3 clips.
(i) Install the scuff plate.
10. Connect heater water valve and engine wire to cowl panel.
11. Connect heater water hose.
12. Connect EVAP hose.
13. Connect brake booster vacuum hose.
14. Install A/C Compressor as follows:
(a) Install the compressor with the 2 bolts hand tight.
(b) Connect the compressor connector.
(c) Using a torx socket (E10), install the stud bolt.
Torque: 26 Nm (265 kg.cm, 19 ft.lb).
(d) Install the nut.
Torque: 52 Nm (530 kg.cm, 38 ft.lb).
(e) Install the 2 mounting bolts.
Torque: 52 Nm (530 kg.cm, 38 ft.lb).
15. Install the Power Steering (PS) pump as follows:
(a) Install the vane pump and bracket with the 2 bolts, tighten as follows:
Bracket to A/C Compressor:
Torque: 58 Nm (590 kg.cm, 43 ft.lb).
Bracket to Cylinder Block:
Torque: 39 Nm (400 kg.cm, 29 ft.lb).
(b) Install the front pump bracket with the 3 bolts and plate washer.
(c) Install the pump rear stay with the 2 bolts.
Torque: 39 Nm (400 kg.cm, 29 ft.lb).
(d) Connect these hoses:
- PS air hose to No.4 timing belt cover
- PS air hose to air intake chamber
16. Connect fuel hoses as follows:
(a) Connect the fuel return hose to the intake manifold stay and No.2 fuel pipe.
(b) Install the fuel inlet hose with 2 new gaskets and union bolt.
Torque: 29 Nm (300 kg.cm, 22 ft.lb).
17. Connect wires and connectors as follows:
(a) Connect the starter wire with the nut and rubber cap.
(b) Connect the ground strap to the LH engine mounting bracket with the bolt.
(c) Connect the generator wire with the nut and rubber cap.
(d) Connect the generator connector.
(e) Connect the wire harness to the wire clamp and coolant reservoir.
(f) Connect the ignition coil connector.
(g) Connect the igniter connector.
18. Install radiator assembly, refer to Cooling System.
19. Install drive belt, refer to Drive Belts, Mounts, Brackets and Accessories.
20. Install air cleaner, Mass Air Flow Meter and intake air connector pipe assembly.
21. Install air cleaner duct.
22. Connect control cables to throttle body.
23. Fill with fuel.
24. Fill with engine oil.
25. Fill with engine coolant.
26. Start engine and check for leaks.
27. Check automatic transmission fluid level.
28. Install engine under cover.
29. Install hood. tighten mounting bolts.
Torque: 13 Nm (130 kg.cm, 9 ft.lb).
NOTE: Be careful not to damage the body or glass with the hood end.
30. Connect hood supports to hood.
Torque: 22 Nm (225 kg.cm, 16 ft.lb).
31. Install hood insulator.
32. Road test, check for abnormal noise, shock slippage, correct shift points and smooth operation.
33. Recheck engine coolant and engine oil levels.