Engine Installation
Step One
1. Tighten all bolts and nuts to the specified torques.
2. Install engine mount No.2 bracket and torque to 44-60 N.m ( 4.4-6.2 Kgf.m, 32-44 Ft.lbs)
Engine mount No.2 rubber
3. Install the engine mount No.2 rubber and hand tighten the through bolt.
Starter
4. Install the starter to the transaxle housing. Tightening torque: 38-51 N.m (3.8-5.3 kgf.m, 28-38 ft.lbs)
Intake manifold bracket
5. Install the intake manifold bracket. Tightening torque: 38-51 N.m (3.8-5.3 kgf.m, 28-38 ft.lbs)
Step Two
Warning: Be sure the vehicle is securely supported on safety stands.
Engine and transaxle assembly
1. Suspend the engine and transaxle assembly. Slowly lower the engine and transaxle assembly as a unit. Keep the engine from swinging or bumping into components in the engine compartment.
2. Position the engine and transaxle assembly in the engine compartment.
3. Align the engine mounts with the engine mount member mounting holes.
Engine mount
1. Hand tighten the nuts marked B. (Engine mount No.2)
2. Install the bolts and nuts as shown. Tightening torque: 67-93 N.m (6.8-9.5 kgf.m, 50-68 ft.lbs)
3. Install the engine mount No.1 mounting bolts. Tightening torque: MTX: 67-93 N.m (6.8-9.5 kgf.m, 50-68 ft.lbs) ATX A: 75-104 N.m (7.6-10.7 kgf.m, 59-82.2 ft.lbs) B: 86-116 N.m (8.7-11.9 kgf.m, 63-86. ft.lbs) C: 67-93 N.m (6.8-9.5 kgf.m, 50-68 ft.lbs)
4. Install the engine mount No.3 rubber. Tightening torque: Nut 74-102 N.m (7.5-10.5 kgf.m, 54.3-75.9 ft.lbs) Bolt 86-116 N.m (8.7-11.9 kgf.m, 63-86.0 ft.lbs)
5. Install the engine mount No.4 bracket.
6. Hand tighten bolts B.
7. Tighten bolts B. 59-80 N.m (6.0-8.2 kgf.m, 44-59 ft.lbs)
8. Tighten bolts A. 59-80 N.m (6.0-8.2 kgf.m, 44-59 ft.lbs)
9. Install the engine mount No.4 rubber. Tightening torque MTX A: 67-93 N.m (6.8-9.5 kgf.m, 50-68 ft.lbs) B: 86-116 Nm (8.7-11.9 kgf.m, 63-86 ft.lbs) ATX B: 38-51 N.m (3.8-5.3 kgf.m, 28-38 ft.lbs)
10. Remove the chain from the engine hangers.
11. Tighten the engine mount No.2 nuts. (Refer to Step 1.) Tightening torque: 75-104 N.m (7.6-10.7 kgf.m, 55-77.3 ft.lbs)
12. Tighten the engine mount No.2 rubber through bolt. Tightening torque: 86-116 N.m (8.7-11.9 kgf.m, 63-86 ft.lbs)
13. Install the engine mount No.5 rubber as shown. Tightening torque: A: 67-93 N.m 16.8-9.5 kgf.m, (50-68 ft.lbs) B: 44-60 N.m 14.4-6.2 kgf.m, 32-44 ft.lbs)
14. Install the engine mount No.1 stay bracket and ground harness (MTX). Tightening torque: 10.8-14.7 N.m (110-150 kgf.cm, 96-130 in.lbf)
Step Three
Joint shaft
1. Install the new clip.
2. Install the joint shaft.
3. Tighten the bolts in the order shown. Tightening torque: 43-61 N.m (4.3-6.3 kgf.m, 32-45 ft.lbs)
4. Apply grease to the end of joint shaft.
Drive shaft
1. Apply grease to the end of the drive shafts.
Caution: The oil seals are damaged easily if this procedure is not done correctly.
2. Install the drive shaft.
3. Install the new clip with the end gap facing upward.
4. Push the drive shaft into the joint shaft.
5. After installation, pull the front hub outward to confirm that the drive shaft is securely held by the clip.
6. Install the lower arm ball joint to the knuckle and tighten the through bolt. Tightening torque: 35-56 N.m 3.5-5.8 kgf.m, 26-41 ft.lbs)
Tie rod end
1. Install the tie rod end to the knuckle. Tightening torque: 32-44 N.m (3.2-4.5 kgf.m, 24-32 ft.lbs)
2. Install a new cotter pin.
Stabilizer control link
1. Install the stabilizer control link. Tightening torque: 37-53 N.m (3.7-5.5 kgf.m, 27-39 ft.lbs)
Extension bar (MTX)
1. Install the extension bar to the transaxle. Tightening torque: 38-51 N.m (3.8-5.3 kgf.m, 28-38 ft.lbs)
Shift control rod (MTX)
1. Install the shift control rod to the transaxle. Tightening torque: 16-22 N.m (1.6-2.3 kgf.m, 12-16 ft.lbs)
Front exhaust pipe
1. Install a new gasket and connect the front exhaust pipe to the exhaust pipe. Hand tighten the new nuts.
2. Connect the exhaust pipe to the vehicle body by the mount rubbers.
3. Tighten the exhaust pipe mounting nuts. Tightening torque: 38-51 N.m (3.8-5.3 kgf.m, 28-38 ft.lbs)
Exhaust pipe
1. Install new gasket and the exhaust pipe. Hand tighten the new nuts.
2. Hand tighten the bracket bolts.
3. Tighten the exhaust pipe mounting nuts. Tightening torque: 38-51 N.m (3.8-5.3 kgf.m, 28-38 ft.lbs)
4. Tighten the bracket bolts. Tightening torque: 38-51 N.m (3.8-5.3 kgf.m, 28-38 ft.lbs)
Transverse member
1. Install the transverse member. Tightening torque: 94-131 N.m (9.5-13.4 kgf.m, 69-96 ft.lbs)
clutch release cylinder
1. Install the clutch release cylinder. Tightening torque: 16-22 N.m (1.6-2.3 kgf.m, 12-16 ft.lbs)
Step Four
1. Connect the hoses shown in the figure.
Step Five
1. Connect the harness connectors.
Step Six
AC compressor (If equipped)
1. Install the A/C compressor to the bracket. Tightening torque: 24-35 N.m (2.4-3.6 kgfm, 18-26 ft.lbs)
P/S oil pump and adjuster
1. Install the P/S oil pump adjuster. Tightening torque: 16-22 N.m (1.6-2.3 kgf.m, 12-16 ft.lbs)
2. Install the P/S oil pump. Tightening torque: A: 44-60 N.m (4.4-6.2 kgf.m, 32-44 ft.lbs) B: 32-46 N.m (3.2-4.7 kgf.m, 24-33 ft.lbs)
3. Connect the P/S oil pump pressure switch connector.
4. Install the P/S pipe brackets to the cylinder head cover. Tightening torque: 7.9-10.7 N.m (80-110 kgf.cm, 70-95.4 in.lbs)
Drive belt
1. Install the drive belt.
2. Adjust the drive belt deflections.
Radiator and coolant fan assembly
1. Install the radiator and coolant fan assembly. Verify that the radiator is centered in the radiator upper brackets. Tightening torque: 19-25 N.m (1.9-2.6 kgf.m, 14-18 ft.lbs)
2. Connect the upper and lower radiator hoses.
3. Connect the coolant reservoir hose.
4. Connect the coolant fan motor connector.
5. Connect the ATF cooler hoses. (ATX)
Accelerator cable
1. Verify that the throttle valve is fully closed.
2. Measure the free play of the accelerator cable. Free play: 1.5-4.0mm (10.06-0.16)
3. If not as specified, adjust the cable free play by turning stopper (A) while pressing lock button (B) with the throttle valve fully closed.
4. Reset the cable lock.
Battery
1. Install the battery. Tightening torque: 7.9-10.7 N.m (80-110 kgf.cm, 70-95.4 in.lbf)
2. Connect the positive battery terminal.
Resonance chamber No.2
1. Slide the hose clamp onto the hose and push it onto resonance chamber No.2.
2. Rotate the hose and hook it securely onto the locating knob.
3. Tighten the hose clamp.
Air cleaner assembly
1. Install the air cleaner assembly. Tightening torque:19-25 N.m 11.9-2.6 kgf.m, 14-18 ft.lbs)
2. Connect the mass airflow sensor connector.
3. Connect the intake air thermosensor connector.
Fresh air duct
1. Install the fresh air duct. Tightening torque: 7.9-10.7 N.m (80-11 kgf.cm, 70-95.4 in.lbf)
Resonance chamber No.1
1. Install resonance chamber No.1. Tightening torque: 7.9-10.7 Nm (80-110 kgf.cm, 70-95.4 in.lbf)
Undercover
1. Install the undercover. Tightening torque: 7.9-10.7 N.m (80-110 kgf.cm, 70-95.4 in.lbf)
Steps After installation
1. Fill with the specified amount and type of engine oil.
2. Fill the radiator with the specified amount and type of engine coolant.
3. Fill with the specified amount and type of transaxle oil.
4. Install the hood and front wheels.
5. Start the engine and: (1) Check the engine oil, transaxle oil, and engine coolant leakage (2) Check the ignition timing, idle speed (3) Check the operation of emission control system
6. Turn oft the engine and check drive belt deflection.
7. Perform a road test.
8. Recheck the engine oil and coolant levels.