Installation Of Engine
1. ASSEMBLE ENGINE AND TRANSAXLE (See pages MT-5 and 6)
2. INSTALL STARTER (See page ST-17)
3. INSTALL LH ENGINE MOUNTING BRACKET
Install the LH mounting bracket to the transaxle case with the three bolts.
4. INSTALL REAR ENGINE MOUNTING BRACKET
Install the mounting bracket with the six bolts. Torque:
14 mm head bolt 530 kg-cm (38 ft-lb, 52 N-m) 17 mm head bolt 790 kg-cm (57 ft-lb, 77 N-m)
5. INSTALL ENGINE AND TRANSAXLE ASSEMBLY IN VEHICLE
(a) Attach the engine chain hoist to the engine hangers.
(b) Slowly lower the vehicle, and raise the engine.
(c) Keep the engine level, and align RH and LH mountings with the body mountings.
(d) Attach the RH mounting insulator to the body, and temporarily install the through bolt.
(e) Attach the RH mounting insulator to the mounting bracket and temporarily install the two nuts.
(f) Attach the LH mounting insulator to the body, and temporarily install the through bolt.
(g) Attach the LH mounting insulator to the mounting bracket, and install the three bolts.
Torque:
A 650 kg-cm (47 ft-lb, 63 Nm) B 740 kg-cm (54 ft-lb, 73 N m)
(h) Tighten the through bolt holding the LH mounting insulator to the body.
(i) Tighten the two nuts holding the RH mounting insulator to the mounting bracket.
(j) Tighten the through bolt holding the RH mounting insulator to the body.
(k) Remove the engine chain hoist from the engine.
6. INSTALL RH ENGINE MOUNTING STAY
Install the mounting stay with the two bolts and nut. Torque: 740 kg-cm (54 ft-lb, 73 Nm)
7. INSTALL LATERAL CONTROL ROD AND AIR CLEANER CASE BRACKET
Install the control rod, case bracket and charcoal canister tube with the five bolts, and connect the ground strap (from transaxle). Do not the tighten the bolt (A).
8. INSTALL LH ENGINE MOUNTING STAY
(a) Install the mounting stay and speedometer cable clamp with the two bolts.
Torque:
Transaxle side 250 kg-cm (18 ft-lb, 25 Nm) Mounting insulator side
9. INSTALL CLUTCH RELEASE CYLINDER AND FRONT ENGINE MOUNTING BRACKET
(a) Place the release cylinder on the transaxle.
(b) Temporarily install the bolt and nut holding the release cylinder to the transaxle.
(c) Install the mounting bracket with the two bolts. Torque: 790 kg-cm (57 ft-lb, 77 N-m)
(d) Tighten the bolt and nut holding the clutch release cylinder to the tranaxle.
10. INSTALL FRONT ENGINE MOUNTING INSULATOR
(a) Install the mounting insulator to the body with the four bolts.
(b) Temporarily install the through bolt and nut holding the mounting insulator to the mpunting bracket.
11. INSTALL REAR SUSPENSION LOWER CROSSMEMBER
(a) Install the lower crossmember with the four bolts. Torque: 1,150 kg-cm (83 ft-lb, 113 N-m)
(b) Install the drive shafts. (See pages SA-66 to 68)
(c) Install the lower suspension arm. (See page SA-77)
(d) Install the stabilizer link to the shock absorber with the nut. Connect the two stabilizer links
(e) Install the wire clamp of the speed sensor with the bolt. Install the two wire clamp.
12. CONNECT SPEEDOMETER CABLE
13. INSTALL REAR ENGINE MOUNTING INSULATOR
(a) Temporarily install the mounting bracket to the body with the three bolts.
(b) Temporarily install the through bolt holding the mounting insulator to the mounting bracket.
(c) Install the mounting bracket to the body with the three bolts.
(d) Tighten the through bolt holding the mounting insulator to the mounting bracket.
14. TIGHTEN FRONT ENGINE MOUNTING THROUGH BOLT
15. INSTALL INTERCOOLER
(See steps 2, 3 (g) and 4 to 7 on page TC-23 and 24)
16. INSTALL A/C COMPRESSOR AND IDLER PULLEY BRACKET
(a) Temporarily install the compressor with the two bolts.
(b) Install the idler pulley bracket with the three bolts. Torque:
A 275 kg-cm (20 ft-lb, 27 N-m) B 375 kg-cm (27 ft-lb, 37 N-m) C 250 kg-cm (18 ft-lb, 25 N-m)
(c) Install the wire clamp of the A/C compressor with the bolt.
(d) Tighten the two bolts of the lower side holding the A/C compressor to the cylinder block.
(e) Connect the A/C compressor connector.
(f) Install and adjust the drive belt with the idler pulley bolt and adjustingibolt.
17. INSTALL ENGINE COMPARTMENT COOLING FAN (See steps 1 and 2 on page CO-36)
18. INSTALL FRONT EXHAUST PIPE
HINT: Passing the exhaust pipe rear side between the body and suspension crossmember is not easy, so follow the method shown in the illustration.
(a) Place a new gasket on the front of the front exhaust pipe.
(b) Using a 14 mm deep socket wrench, install the three new nuts holding the exhaust pipe to the catalytic converter.
(c) Install the support bracket with the two bolts. Torque: 210 kg-cm (15 ft-lb, 21 N-m)
19. INSTALL TAILPIPE
(a) Install the tailpipe with the two through bolts.
(b) Place a new gasket between the front exhaust pipe and tailpipe.
(c) Temporarily install the two bolts holding the front exhaust pipe to the tailpipe.
(d) Install the two bolts holding the stopper bracket of the front exhaust pipe to the tailpipe stopper bracket.
(e) Tighten the two bolts holding the front exhaust pipe to the tailpipe.
20. CONNECT TRANSAXLE CONTROL CABLES TO
TRANSAXLE
21. CONNECT FUEL INLET HOSE TO FUEL FILTER Torque: 300 kg-cm (22 ft-lb, 29 N-m)
22. CONNECT FUEL RETURN HOSE
23. CONNECT RADIATOR HOSE TO WATER OUTLET
24. CONNECT HEATER HOSES
27. CONNECT ENGINE WIRE TO LUGGAGE COMPARTMENT
(a) Push in the engine wire through the luggage compartment.
(b) Connect the following connectors:
(1) Two engine ECU connectors
(2) Starter relay connector
(3) Engine comparment cooling fan relay connector
(4) Engine compartment wire connector
28. INSTALL IGNITION COIL AND IGNITER
(a) Install the ignition coil and igniter assembly with the two bolts. Connect the noise filter.
(b) Connect the high-tension cord.
(c) Connect the ignition coil connector.
(d) Connect the igniter connector.
29. CONNECT ENGINE WIRE, AND INSTALL ENGINE RELAY BOX
(a) Connect the two connectors and positive (+) cable of the engine wire to the relay box.
(b) Install the upper and lower covers to the relay box.
(c) Install the relay box with the two bolts. Install the luggage compartment striker cable.
30. INSTALL CHARCOAL CANISTER
(a) Install the charcoal canister with the two bolts.
(b) Connect the three hoses.
31. INSTALL WATER FILLER
(a) Install the water filler with the two bolts.
(b) Connect the following hoses:
(1) Water filler hose
(2) Coolant reservoir hose
32. INSTALL INJECTOR SOLENOID RESISTOR, FUEL
PUMP RELAY, FUEL PUMP RESISTOR AND A/C VSV
(a) Install the solenoid resistor, fuel pump relay, fuel pump resistor assembly and A/C VSV with the two bolts.
(b) Connect the following hoses:
(2) A/C VSV vacuum hose from intake manifold
(c) Connect the following connectors:
• Solenoid resistor connector
• Fuel pump relay connector
• Fuel pump resistor connector
33. INSTALL CHECK CONNECTOR AND
TURBOCHARGING PRESSURE SENSOR
Install the check connector and turbocharging pressure sensor with the bolt.
34. CONNECT BRAKE BOOSTER VACUUM HOSE
35. CONNECT GROUND STRAP CONNECTOR
36. INSTALL CRUISE CONTROL ACTUATOR (w/ CRUISE CONTROL SYSTEM) AND ACCELERATOR LINKAGE
(a) Connect the cable to the accelerator linkage.
(b) Install the accelerator linkage with the three bolts.
(c) Connect the actuator connector.
(d) Install the actuator with the three bolts.
(e) Install the accelerator linkage cover with the screw.
(f) Install the actuator cover with the two screws.
37. INSTALL ACCELERATOR CABLE, AND ADJUST IT
38. INSTALL NO.1 AIR INTAKE CONNECTOR
39. INSTALL NO.2 AIR INTAKE CONNECTOR
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40. INSTALL AIR CLEANER
(a) Install the air cleaner case with the three bolts.
(b) Install the air cleaner element.
(c) Connect the following hose:
(1) Air cleaner hose from turbocharger
(2) PCV hose from cylinder head cover
(3) Air hose from No.2 air tube
(4) Air hose from air by-pass valve
(d) Install the air cleaner cap and air flow meter.
(e) Connect the air flow meter connector.
41. INSTALL SUSPENSION UPPER BRACE
Install the suspension upper brace with the two bolts and two nuts.
Torque: Bolt 740 kg-cm (54 ft-lb, 73 N-m) Nut 650 kg-cm (47 ft-lb, 64 N-m)
42. CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY
43. FILL WITH ENGINE COOLANT (See page CO-7)
Capacity (w/ Heater):
44. FILL WITH ENGINE OIL (See page LU-8)
Capacity:
Drain and refill w/ Oil filter change
3.9 liters (4.1 US qts, 3.4 Imp. qts) w/o Oil filter change
3.6 liters (3.8 US qts, 3.2 Imp. qts) Dry fill 4.3 liters (4.5 US qts, 3.8 Imp. qts)
45. START ENGINE AND CHECK FOR LEAKS
46. PERFORM ENGINE ADJUSTMENT
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