Engine Installation

1) Install engine onto transmission.





a) Position engine in engine compartment and align it with transmission.

CAUTION: Be careful not to damage adjacent parts or body panels with crank pulley, oil pressure gauge, etc.

b) Apply a small amount of grease to splines of mainshaft.





2) Tighten bolts which hold upper side of transmission to engine.
Tightening torque: 50 ± 4 Nm (5.1 ± 0.4 kg-m, 36.9 ± 2.9 ft. lbs.)





3) Remove lifting device and wire ropes.
4) Remove garage jack.





5) Install pitching stopper.
Tightening torque:
T1: 49 ± 5 Nm (5.0 ± 0.5 kg-m, 36.2 ± 3.6 ft. lbs.)
T2: 57 ± 10 Nm (5.8 ± 1.0 kg-m, 42 ± 17 ft. lbs.)
6) Install torque converter onto drive plate. (AT model)
a) Tighten bolts which hold torque converter to drive plate.





b) Tighten other bolts while rotating the engine by using ST.
b200 cc vehicles: ST 499977300 CRANK PULLEY WRENCH
b500 cc vehicles: ST 499977100 CRANK PULLEY WRENCH

CAUTION: Be careful not to drop bolts into torque converter housing.

Tightening torque: 25 2 Nm (2.5 ± 0.2 kg-m, 18.1 ± 1.4 ft. lbs.)
c) Clog plug onto service hole.
7) Install power steering pump on bracket.





a) Install power steering pump on bracket, and tighten bolts.
Tightening torque: 39±10 Nm (4.0 ± 1.0 kg-m, 29 ± 7 ft. lbs.)





b) Install power steering pipe bracket on right side intake manifold, and install spark plug codes.





c) Install front side V-belt, and adjust it.





8) Tighten nuts which hold lower side of transmission to engine.
Tightening torque: 50 ± 4 Nm (5.1 ± 0.4 kg-m, 36.9 ± 2.9 ft. lbs.)





9) Tighten nuts which install front cushion rubber onto crossmember.
Tightening torque: 69 ± 15 Nm (7.0 ± 1.5 kg-m, 51 ± 11 ft. lbs.)

CAUTION:
Be sure to tighten front cushion rubber mounting bolts in the innermost elliptical hole in the front

10) Install front exhaust pipe and center exhaust pipe.
11) Connect rear oxygen sensor connector.
12) Connect the following hoses.
a) Fuel delivery hose, return hose and evaporation hose
b) Heater inlet and outlet hoses
c) Brake booster vacuum hose
d) Cruise control vacuum hose (With cruise control)
13) Connect the following connectors.
a) Engine ground terminal
b) Engine harness connectors
c) Front oxygen sensor connector
d) Alternator connector and terminal
e) A/C compressor connectors (With A/C)
14) Connect the following cables.
a) Accelerator cable
b) Cruise control cable (With crude control)
c) Clutch cable (2200 cc MT vehicle)
d) Clutch release spring (2200 cc MT vehicle)

CAUTION: After connecting each cable, adjust them.

15) Install air intake system.
a) Install air cleaner element.
b) Install air intake duct with air cleaner case.





16) Install A/C flexible hoses. (With A/C).

CAUTION: Use new O-rings.

Tightening torque: 25 ± 7 Nm (2.5 ± 0.7 kg-m, 18.1 ± 5.1 ft. lbs.)
17) Install cooling system.





a) Attach radiator mounting cushions to pins on lower side of radiator.





b) Fit cushions on lower side of radiator, into holes on body side and install radiator.





c) Install radiator brackets and tighten bolts.
Tightening torque: 13.7 ± 1.5 Nm (1.4 ± 0.15 kg-m, 10.1 ± 1.1 ft. lbs.)





d) Connect radiator inlet hose.





e) Connect radiator fan motor connector.





f) Connect radiator outlet hose.
g) Connect ATF cooler hoses. (AT vehicles)
h) Install ATF cooler pipe to cylinder head. (2200 cc AT vehicle)





i) Install V-belt cover.
18) Install battery in the vehicle, and connect cables.
19) Fill coolant.
20) Check ATF level and correct if necessary. (AT model).
21) Charge A/C system with refrigerant.
22) Remove front hood stay, and close front hood.
23) Remove the vehicle from lift arms.