Installation

1. Assemble engine and transaxle. See Transmission and Drivetrain.
2. Install starter. See Starting and Charging.





3. Install rear engine mounting bracket. Tighten the 2 bolts (3 A/T) or 3 bolts (Except 3A/T) holding the mounting bracket to the transaxle. Torque to 77 Nm (57 ft. lbs.).





4. Install front engine mounting bracket. Tighten the 2 bolts holding the mounting bracket to the transaxle. Torque to 77 Nm (57 ft. lbs.).
5. Install engine and transaxle assembly in vehicle as follows:
a. Attach the engine sling device to the engine hangers.





b. Lower the engine into the engine compartment. Tilt the transaxle downward, lower the engine and clear the LH mounting.

CAUTION: Be careful not to hit the power steering gear housing and throttle position sensor.

c. Keep the engine level, and align RH and LH mountings with the body bracket.





d. Install the LH mounting bracket with the 3 bolts. Torque to 52 Nm (38 ft. lbs.).
e. Attach the RH mounting insulator to the body, and temporarily install the 3 bolts.
f. Attach the RH mounting insulator the mounting bracket, and temporarily install the bolt and 2 nuts.
g. Attach the LH mounting insulator to the body, and temporarily install the through bolt.





h. Attach the Lid mounting insulator to the mounting bracket, and install the 3 bolts. Torque to 56 Nm (41 ft. lbs.).
i. Tighten the through bolt holding the LH mounting insulator to the body. Torque to 87 Nm (64 ft. lbs.).





j. Install the mounting stay with the 2 bolts. Torque to 21 Nm (15 ft. lbs.).





k. Tighten the 4 bolts and 2 nuts holding the RH mounting insulator to the body and mounting bracket. Torque to:
A: 64 Nm (47 ft. lbs.).
B: 52 Nm (38 ft. lbs.).
C: 25 Nm (19 ft. lbs.).
l. Install the A/C damper with the bolt.
m. Install the A/C bracket with the bolt and screw.
n. Install the cruise control actuator bracket and ground wire with the 3 bolts.
o. Remove the engine chain hoist from the engine.
p. Remove the bolt and engine hanger No. 1.
6. Connect engine mounting center member as follows:





a. Temporarily install the center member to the body with the 5 bolts and 4 nuts.





b. Tighten the through-bolt holding the rear engine mounting insulator to the rear mounting bracket. Torque to 87 Nm (64 ft. lbs.).





c. Tighten the 5 bolts and 4 nuts holding the center member to the body. Torque to:
- Bolt A: 61 Nm (45 ft. lbs.).
- Bolt B: 64 Nm (47 ft. lbs.).
- Bolt C: 48 Nm (35 ft. lbs.).
- Nut: 57 Nm (42 ft. lbs.).
d. Install the 2 hole covers.





7. Install front engine mounting insulator. Tighten the through bolt and nut holding the mounting insulator to the mounting bracket. Torque to 87 Nm (64 ft. lbs.).
8. Install drive shafts. See Transmission and Drivetrain.
9. Install front exhaust pipe as follows:
a. Place 2 new gaskets to the front and rear of the front exhaust pipe.
b. Using a 14 mm deep socket wrench, install the front exhaust pipe with 2 new nuts. Torque to 62 Nm (46 ft. lbs.).
c. Install the 2 bolts and support bracket holding the front exhaust pipe to the exhaust manifold. Torque to 43 Nm (32 ft. lbs.).
d. Install the 2 bolts holding the front exhaust pipe bracket to the mounting bracket. Torque to 19 Nm (14 ft. lbs.).
e. Connect the oxygen sensor connector.





10. Install Power Steering (PS) pump as follows:
a. Install the PS pump with the 2 bolts. Torque to 39 Nm (23 ft. lbs.).
b. Install the drive belt.





11. Install A/C compressor as follows:
a. Install the compressor with the 3 bolts. Torque to 25 Nm (18 ft. lbs.).
b. Install the drive belt.
c. Connect the A/C compressor connector.
12. Connect engine wire to cabin as follows:
a. Push in the engine wire through the cowl panel.
b. Connect the following connectors:
(1) 3 ECM connectors.
(2) Cowl wire connector.
c. Install the floor carpet bracket.
d. Install the finish lower center panel.
e. A/T: Install the shifting hole bezel.
f. M/T: Install the shift lever knob.
g. Install the rear console box.
h. Install the center cluster finish panel.
i. Install the radio.
j. Install the lower panel with glove compartment door.
k. Install the RH front door scuff plate.
l. Install the lower finish panel.
m. Install the LH front door scuff plate.
13. Connect transaxle control cable(s) to transaxle
14. Install clutch release cylinder. Install the release cylinder and tube with the 3 bolts. M/T only.





15. Connect fuel return hose.
16. Connect fuel inlet hose. Torque to 29 Nm (22 ft. lbs.).
17. Connect heater hoses. Connect the 2 heater hoses to the water inlet housing.
18. Install charcoal canister as follows:
a. Connect the hose to charcoal canister.
b. Install the charcoal canister to the bracket.
19. Connect wires and connectors as follows:
a. Connect the 4 connectors to the engine relay box.
b. Install the engine relay box with the 2 bolts.





c. LH Fender apron side connect the following wire and connectors:
(1) DLC1 connector.
(2) Connector from fender apron.
(3) Ground strap from fender apron.





d. RH fender apron side connect the following wire and connectors:
(1) Ground strap connector.
(2) Manifold Absolute Pressure (MAP) connector.
(3) A/C pressure switch.
(4) Engine wire from fender apron.





20. Connect hoses and connector as follows:
a. Connect the A/C actuator connector.
b. Connect the air hoses to the air pipe.
c. Connect the following vacuum hoses to the intake chamber:
(1) MAP hose to gas filter.
(2) Brake booster vacuum hose.
(3) A/C vacuum hose from actuator.





21. Install cruise control actuator as follows:
a. Install the actuator and bracket with the 3 bolts.
b. Connect the actuator connector.
c. Connect the cruise control actuator cable to the actuator.
d. Install the actuator cover.
22. Install washer tank as follows:
a. Connect the connector and vinyl hose to the washer tank.
b. Install the washer tank with the bolt.
23. Install coolant reservoir tank stay. Install the stay with the bolts.
24. Install air cleaner assembly as follows:
a. Install the air cleaner case with the 3 bolts.
b. Connect the harness clamp to the boss of the case.
c. Install the air cleaner filter element.
d. Connect the air cleaner hose, and install the air cleaner cap with the 4 clips.
e. Tighten the air cleaner hose clamp bolt.
f. Connect the Intake Air Temperature (IAT) sensor connector to the air cleaner cap.
25. Install radiator with cooling fan. See Cooling System.
26. Connect throttle cable, and adjust it. A/T only.
27. Install accelerator cable, and adjust it.
28. Fill radiator with engine coolant.
29. Fill with engine oil.
30. Fill with transaxle oil.
31. Start engine and check for leaks.
32. Perform engine adjustment.
33. Install engine under covers.
34. Install hood. See Body and Frame.
35. Perform road test. Check for abnormal noises, shock slippage, correct shift points and smooth operation.
36. Recheck engine coolant and oil levels.