Installation

INSTALLATION





1. Install drive plate.
a. Install the front spacer, drive plate and rear plate on the crankshaft.





b. Apply adhesive to 2 or 3 threads of the mounting bolt end.

Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent

c. Install the uniformly tighten the 8 mounting bolts, in several passes, in the sequence shown.

Torque: 83 Nm (61 ft. lbs.)






2. Install transmission to engine
a. Check the torque converter clutch installation.
b. Attach the transmission to the engine.
c. Install the ground wire and 5 bolts.

Torque: 72 Nm (53 ft. lbs.)

3. Connect engine wire to transmission.
Connect these connectors and wire:
- VSS connector
- PNP switch connector
- Solenoid connector
- Direct clutch speed sensor connector
- Engine wire to 3 wire clamps
4. Install starter.
a. Install the starter and clamp bracket with the 2 bolts.

Torque: 37 Nm (27 ft. lbs.)

b. Connect the starter connector.





5. Install 4 bolts holding No.1 oil pan to transmission.

Torque: 37 Nm (27 ft. lbs.)

6. 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: 48 Nm (35 ft. lbs.)

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

c. Install the hole plug.
7. Install oil cooler pipe for A/T.





8. Install exhaust manifold.
a. Install 2 new gaskets to the cylinder head.
b. Using a 14 mm deep socket wrench, install the exhaust manifold with the 8 nuts. Uniformly tighten the nuts in several passes.

Torque: 40 Nm (30 ft. lbs.)

c. Connect the heated oxygen sensor (bank 2 sensor 1) connector.
d. Install the case clamp.





9. Install oil dipstick guide and dipstick for A/T.
a. Install a new O-ring to the dipstick guide.
b. Push in the dipstick guide end to the dipstick tube of the oil pan.
c. Install the dipstick guide with the bolt.
d. Connect the engine wire clamp to the dipstick guide.
f. Install the dipstick.





10. Install engine and transmission assembly in vehicle
a. Attach the engine chain hoist to the engine hangers.
b. Slowly lower the engine and transmission assembly into the engine compartment.
c. Insert the stud bolts of the front engine mounting brackets into the stud bolt holes of the front suspension crossmember.
d. Keep the engine level.





e. Install the rear engine mounting member with the 4 bolts and 4 nuts.

Torque:
25.5 Nm (19 ft. lbs.) for bolts
13.5 Nm (10 ft. lbs.) for nuts

NOTICE: Be careful of installation direction.






f. Install the 4 nuts holding the engine mounting brackets to the front suspension crossmember.

Torque: 70 Nm (52 ft. lbs.)

g. Install the 2 hole plugs.
h. Remove the engine chain hoist.
i Remove the bolt and No.1 engine hanger.





11. Install PS gear housing.
a. Align the matchmarks and connect the sliding yoke to the steering intermediate shaft.
b. Install the PS gear housing with the 4 bolts.

Torque: 65 Nm (48 ft. lbs.)





c. Install the bolt holding the sliding yoke to the steering intermediate shaft.

Torque: 35 Nm (26 ft. lbs.)

d. Connect the PS pressure switch and wire clamp.





12. Install transmission control rod.
Install the control rod with the 2 nuts.

Torque: 13 Nm (9 ft. lbs.)





If the indicator is not aligned with the correct position, carry out the following adjustment procedures.
1) Loosen the nut on the shift lever.
2) Push the control shaft lever fully rearward.
3) Return the control shaft lever 2 notches to the Nm position.
4) Set the shift lever to the Nm position.
5) While holding the shift lever lightly toward the R position side, tighten the nut.

Torque: 13 Nm (9 ft. lbs.)





13. Install A/C compressor and PS pump.
a. Temporarily install the compressor with the 2 bolts.
b. Using a torx socket (E10), install the stud bolt.

Torque: 26 Nm (19 ft. lbs.)

c. Tighten the nut and 2 bolts.

Torque: 52 Nm (38 ft. lbs.)

d. Connect the compressor connector.
e. Connect the PS solenoid valve connector.





f. Install the vane pump assembly with the 3 bolts and plate washer.

Torque:
57.9 Nm (43 ft. lbs.) for A bolts
52 Nm (38 ft. lbs.) for B bolt





g. Install the pump rear stay with the 2 bolts.

Torque: 39.2 Nm (29 ft. lbs.)

h. Connect these hoses:
- PS air hose to No.4 timing belt cover
- PS air hose to air intake chamber





14. Connect engine wire to ECM box.
a. Install the engine wire grommet to the ECM box.
b. Connect these connectors:
- 3 ECM connectors
- 4 wire harness connectors
- 2 junction connectors
c. Install these parts:
- ECM cover
- ECM hood





15. Connect clamps, wires, connectors, hoses, cable and strap.
- 2 engine wire clamps to clamp brackets
- DLC1
- Igniter connector
- Ground cable to bracket on cylinder block
- Engine wire clamp to wire clip of generator
- Generator wire
- Heated oxygen sensor (bank 1 sensor 1) connector
- Heated oxygen sensor (bank 1 sensor 2) connector





- EVAP hose to pipe (from charcoal canister)
- Heater hose to heater pipe
- Heater hose to water bypass pipe
- Ground strap to dash panel
- Fuel inlet hose to fuel pipe support

Torque: 29 Nm (22 ft. lbs.)

- Starter wire to terminal and manifold stay
- Ground wire to floor





16. Install front suspension member brace.
Install the brace with the 6 bolts.

Torque: 58 Nm (43 ft. lbs.)

17. Install drive belt.
18. Install radiator assembly.
19. Connect accelerator cable to engine.





20. Install air cleaner, map meter and intake air connector pipe assembly.
a. Connect the intake air resonator to the throttle body.
b. Install the air cleaner case with the 3 bolts.
c. Tighten the hose clamp bolt holding the intake air resonator to the throttle body.
d. Connect the connector, clamp and hoses:
- MAF meter connector
- Engine wire clamp to air cleaner case
- EVAP hose to air cleaner case
- PS air hose to No.4 timing belt cover
PCV hose to No.2 cylinder head cover
21. Install air cleaner inlet.
22. Fill with engine coolant.
23. Fill with engine oil.
24. Start engine and check for leaks.
25. Install engine under cover.
26. Install hood.

NOTICE: Be careful not to damage the body or glass with the hood end.

27. Perform road test.
Check for abnormal noise, shock, slippage, correct shift points and smooth operation.
28. Recheck engine coolant and oil levels.