Installation

1. M/T only: Install clutch disc and cover.
2. Assemble engine and transaxle.
3. 2WD: Install drive shaft bearing bracket.
Torque: 64 Nm (47 ft. lbs.)
4. Install engine and transaxle assembly in vehicle.

(a) Attach the engine sling device to the engine hangers.
(b) Slowly lower the vehicle, and raise the engine into the engine compartment.
(c) Keep the engine level, and align RH and LH mountings with the body mountings.

(d) Attach the RH engine mounting bracket to the mounting insulator, and temporarily install the bolt and 2 nuts.

(e) Attach the LH engine mounting bracket to the mounting insulator, and install the 2 nuts and 2 bolts.
Torque: 64 Nm (47 ft. lbs.)

(f) Tighten the bolt and 2 nuts holding the RH engine mounting bracket to the mounting insulator.
Torque:
Bolt: 37 Nm (27 ft. lbs.)
Nut: 52 Nm (38 ft. lbs.)
(g) Connect the ground strap connector.
(h) Remove the engine sling device from the engine.
(i) Remove the engine hanger No. 1.
5. Install Power Steering (PS) pump.

(a) Install the PS pump with the 3 bolts.
Torque: 43 Nm (32 ft. lbs.)

(b) Install the belt.
(c) Tighten the bolt A.
Torque: 39 Nm (29 ft. lbs.)
(d) Using Special Service Tool (SST) Torque Wrench Adaptor # 09249 - 63010 or equivalent and a deep socket wrench, tighten the bolt B.
Torque:
43 Nm (32 ft. lbs.)
30 Nm (22 ft. lbs.) for SST

NOTE: Use a torque wrench with a fulcrum length of 340 mm (13.39 inch).

(e) Connect the 2 air hoses.

6. Install engine mounting center member.
(a) Attach the center member to the body.
(b) Temporarily install the 2 bolts holding the center member to the body.
(c) Temporarily install the 2 bolts holding the center member to the front engine mounting insulator.
7. Install front suspension crossmember.
(a) Support the front suspension crossmember with a jack.

(b) Attach the front suspension crossmember to the body, and temporarily install the 6 bolts.

(d) Temporarily install the PS gear assembly with the 2 bolts and 2 nuts.

(f) Tighten the 6 bolts holding the front suspension crossmember to the body.
Torque:
Bolt A: 206 Nm (152 ft. lbs.)
Bolt B: 137 Nm (101 ft. lbs.)
(g) Tighten the 2 bolts and 2 nuts holding the PS gear assembly to the front suspension crossmember.
Torque: 113 Nm (83 ft. lbs.)
(h) Tighten the 2 nuts holding the front suspension crossmember, engine mounting center member to the rear engine mounting insulator.
Torque: 112 Nm (82 ft. lbs.)
(i) Tighten the 2 bolts holding the engine mounting center member to the front engine mounting insulator.
Torque: 80 Nm (59 ft. lbs.)
(j) Tighten the 2 bolts holding the engine mounting center member to the body.
Torque: 35 Nm (26 ft. lbs.)
8. Install stabilizer. Refer to Steering and Suspension.
9. Install front drive shaft. Refer to Transmission and Drivetrain.
10. 4WD only: Install propeller shaft. Refer to Transmission and Drivetrain.
11. Install A/C compressor.

(a) Install the A/C compressor with the 2 bolts, stud bolt and nut.
Torque:
Stud bolt: 47 Nm (34 ft. lbs.)
Bolt: 37 Nm (27 ft. lbs.)
Nut: 27 Nm (20 ft. lbs.)
(b) Connect the A/C compressor connector.

12. Install front exhaust pipe.
(a) Place 2 new gaskets to the front and rear of the front exhaust pipe.
(b) Temporarily install 3 new nuts holding the front exhaust pipe to the front Three-Way Catalytic Converter (TWC).
(c) Temporarily install the 2 bolts holding the front exhaust pipe to the TWC w/ pipe.
(d) Using a 14 mm deep socket wrench, tighten the 3 nuts holding the front exhaust pipe to the front TWC.
Torque: 62 Nm (46 ft. lbs.)
(e) Tighten the 2 bolts holding the front exhaust pipe to the TWC w/ pipe.
Torque: 48 Nm (35 ft. lbs.)
13. Connect engine wire to cabin.
(a) Push in the engine wire through the cowl panel.

(b) Install the wire clamp to the bracket.
(c) Connect the wire and connectors:
- 2 Engine Control Module (ECM) connectors.
- 2 connectors to connectors on bracket.
- Connector to Junction Block (J/B) No. 4.
(d) Install these parts:
- RH floor Carpet center cover.
- RH cowl side trim.
- RH scuff plate.
14. Connect connectors, cord, strap and hoses.
Connect the connectors, cord, strap and hoses:
- Vapor pressure sensor connector.
- Igniter connector.
- Ignition coil connector.
- Noise filter connector.
- High-tension cord from ignition coil.
- Manifold Absolute Pressure (MAP) sensor connector.
- MAP sensor vacuum hose from gas filter on intake manifold.
- Brake booster hose from intake manifold.
- 4WD M/T: Differential lock control solenoid connector.
- Ground strap from cowl.
15. A/T and 4WD w/ M/T: Connect transaxle oil cooler hoses.

16. Connect transaxle control cable(s) to transaxle.

17. A/T only: Install transaxle control cable to front suspension crossmember and engine mounting center member.

18. M/T only: Install clutch release cylinder.
(a) Install the release cylinder with the 2 bolts.
Torque: 12 Nm (9 ft. lbs.)
(b) Install the bracket with the bolt, and install the tube to the bracket with the clamp.
(c) Install the tube with the clamp and bolt.
(d) Connect the back-up light switch connector.
19. Connect ground cable.
Connect the ground cable onto the transaxle.
20. M/T only: Install starter. Refer to Starting and Charging.
21. Connect fuel inlet hose to fuel filter.
Connect the inlet hose with 2 new gaskets and the union bolt.
Torque: 29 Nm (22 ft. lbs.)
22. Connect heater hoses.
23. Install water inlet.
Install the water inlet with the 2 nuts.
Torque: 8.8 Nm (78 inch lbs.)
24. Install radiator upper and lower hoses.
25. Install generator. Refer to Starting and Charging.
26. Install charcoal canister.

27. Connect engine wire to relay box No. 2.
(a) Connect the engine wire to the relay block No. 2 with the 2 nuts.
(b) Connect the connector.
(c) Install the upper cover.
(d) Connect the relay block No. 2 to the body with the 2 bolts
28. Install accelerator cable to throttle body, cable bracket and clamps.
29. Install air cleaner case and cap.
30. Install battery.
31. Fill with transaxle oil.
32. Fill with engine oil.
33. Fill with engine coolant.
34. Start engine and check for leaks.
35. Perform engine adjustment.
36. Check front wheel alignment.
37. Install engine under covers.
38. Install engine hood.
39. Road test vehicle.
Check for abnormal noises, shock slippage, correct shift points and smooth operation.
40. Recheck engine coolant and oil levels.