Installation
INSTALLATION1. ASSEMBLY ENGINE AND TRANSMISSION
2. INSTALL STARTER
3. CONNECT ENGINE WIRE TO TRANSMISSION
4. INSTALL OIL COOLER PIPES
5. INSTALL OIL DIPSTICK GUIDE AND DIPSTICK FOR A/T
a. Install a new O-ring to the dipstick guide.
b. Apply new oil to the O-ring.
c. Connect the dipstick guide end to the dipstick tube of the oil pan.
d. Install the dipstick guide with the bolt.
e. Install the dipstick.
6. INSTALL ENGINE AND TRANSMISSION ASSEMBLY IN VEHICLE
a. Attach the engine hoist chain to the engine hangers.
b. Lower the engine and transmission assembly into the engine compartment.
NOTICE: Install the engine and transmission assembly carefully without damaging the A/C compressor and PS solenoid valve.
c. Insert the stud bolts of the front engine mounting insulators into the stud bolt holes of the front suspension crossmember.
d. Temporarily install the 2 nuts holding the engine front mounting insulators to the front suspension crossmember.
e. Keep the engine level with a jack.
f. Remove the hoist chain.
g. Remove the bolt and No.1 engine Hanger.
h. Temporarily install the support member to the engine rear mounting insulator with the 4 nuts.
i. Install the 4 bolts holding the support member to the body.
Torque: 25 Nm (19 ft. lbs.)
j. Tighten the 4 nuts holding the support member to the engine rear mounting insulator.
Torque: 13 Nm (10 ft. lbs.)
k. Tighten the 2 nuts holding the engine front mounting insulators to the front suspension crossmember.
Torque: 59 Nm (43 ft. lbs.)
7. CONNECT TRANSMISSION CONTROL ROD
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 (9 ft. lbs.)
8. INSTALL INTERMEDIATE SHAFT
a. Remove the SST from the yoke of the transmission.
SST 09325 40010
b. Insert the yoke into the transmission.
c. Align the matchmarks on the flanges, and connect the propeller shaft with the 4 bolts, washers and nuts.
d. Torque the bolts and nuts.
Torque: 74 Nm (54 ft. lbs.)
e. Temporarily install the center support bearing set bolts with the adjusting washers.
HINT: Use the adjusting washers which were removed.
f. Torque the bolts, and inspect the joint angle.
Torque: 49 Nm (36 ft. lbs.)
9. INSTALL EXHAUST PIPE HEAT INSULATOR
Install the heat insulator with the 4 nuts.
10. INSTALL EXHAUST MANIFOLD
11. INSTALL STARTER WIRE AND FUEL INLET HOSE
a. Install the ground strap to the transmission.
b. Install the starter wire with the nut.
c. Install the starter wire with the wire clamp.
d. Install the fuel inlet hose with 2 new gaskets and the union bolt.
Torque: 29 Nm (22 ft. lbs.)
12. INSTALL PS PRESSURE FEED HOSE
Install the pressure feed hose with the 2 clamp bolts.
13. CONNECT ENGINE WIRE TO CABIN
a. Push in the engine wire through the cowl panel.
b. Connect these connectors:
1) 6 connectors to ECM
2) 4 connectors to connector cassette
3) Connector to A/C control assembly
c. Install the ECM protector with the 2 nuts.
d. Install the floor carpet.
e. Install the scuff plate.
f. Connect the connectors.
g. Install the lower instrument panel finish panel and glove compartment door assembly with the 4 screws.
h. Install the instrument panel under cover with the 2 clips.
14. CONNECT CONNECTOR, WIRES AND HOSES
a. Install the engine wire clamp with the 2 bolts.
b. Install the bolt holding the engine wire protector to the water valve bracket.
c. Install the bolt holding the engine wire protector to the body.
d. Install the ground strap to the bracket on the body.
e. Connect the VSV connector.
f. Connect these hoses:
- Heater hose to water bypass pipe
- Heater hose to heater water valve
- Vacuum hose (from VSV for heater water valve) to check valve
g. Install the generator wire with the nut and cap.
h. Connect the engine wire to the wire clamp.
i. Connect the PS pressure switch connector.
j. Install the ground cable on the cylinder block.
k. Connect the PPS solenoid valve connector and wire clamp.
l. Using a 6 mm hexagon wrench, install the connector bracket with the bolt.
m. Connect these connectors:
- 2 connectors to engine room main wire
- Igniter connector
- Theft deterrent horn connector
- Noise filter connector
n. Install the engine wire with the 2 wire clamps.
15. INSTALL A/C COMPRESSOR
a. Using a torx socket (E10), install the stud bolt and compressor.
Torque: 26 Nm (19 ft. lbs.)
b. Connect the compressor connector.
c. Install the compressor with the nut and 2 bolts.
Torque: 52 Nm (38 ft. lbs.)
16. INSTALL PS PUMP
a. Install the PS pump assembly with the 3 bolts and play washer.
Torque:
58 Nm (43 ft. lbs.) for A
52 Nm (38 ft. lbs.) for B
b. Install the pump rear stay with the 2 bolts.
Torque: 39 Nm (29 ft. lbs.)
c. Connect these hoses:
- PS air hose to No.4 timing belt cover
- PS air hose to air intake chamber
17. CONNECT EVAP HOSE TO VSV FOR EVAP
18. CONNECT BRAKE BOOSTER VACUUM HOSE TO UNION
19. INSTALL WATER PUMP PULLEY, FAN, FLUID COUPLING ASSEMBLY AND DRIVE BELT
20. INSTALL RADIATOR ASSEMBLY
21. INSTALL AIR CLEANER, MAF METER AND INTAKE AIR CONNECTOR PIPE ASSEMBLY
a. Connect the air cleaner case to the air duct.
b. Connect the intake air connector pipe to the throttle body.
c. Install the air cleaner, MAF meter and intake air connector pipe assembly with the 4 bolts.
d. Tighten the hose clamp bolt holding the intake air connector pipe to the throttle body.
e. Connect these hoses: PS air hose to No.4 timing belt cover PCV hose to No.2 cylinder head cover EVAP hose to air cleaner
f. Connect the MAF meter connector.
22. CONNECT ACCELERATOR CABLE TO THROTTLE BODY
23. FILL WITH ENGINE OIL
24. FILL WITH ENGINE COOLANT
25. START ENGINE AND CHECK FOR LEAKS
26. CHECK AUTOMATIC TRANSMISSION FLUID LEVEL
27. INSTALL ENGINE UNDER COVER
28. INSTALL HOOD
29. ROAD TEST
Check for abnormal noise, shock slippage, correct shift points and smooth operation.
30. RECHECK ENGINE COOLANT AND ENGINE OIL LEVELS