MECHANICAL(H4DOTC) > Engine Assembly

INSTALLATION

1. Install the engine mounting onto the engine.

Tightening torque:

35 N·m (3.6 kgf-m, 25.8 ft-lb)

2. Apply a small amount of grease to splines of main shaft. (MT model)

Grease:

NICHIMOLY N-130 or equivalent

3. Position the engine in engine compartment and align it with transmission.

NOTE:

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

4. Tighten the bolts which hold upper side of transmission to engine.

Tightening torque:

50 N·m (5.1 kgf-m, 36.9 ft-lb)

AT model

MT model

5. Remove the lifting device and wire ropes.

6. Remove the garage jack.

7. Install the pitching stopper.

Tightening torque:

T1: 50 N·m (5.1 kgf-m, 36.9 ft-lb)

T2: 58 N·m (5.9 kgf-m, 42.8 ft-lb)

8. Remove the ST from the torque converter clutch case. (AT model)

NOTE:

Be careful not to drop the ST into the torque converter clutch case when removing the ST.

ST    498277200 STOPPER SET

9. Install the starter.

10. Install the torque converter clutch to drive plate. (AT model)

(1) Tighten the bolts which hold torque converter clutch to drive plate.

(2) Tighten other bolts while rotating the crankshaft using socket wrench.

NOTE:

Be careful not to drop bolts into the torque converter clutch housing.

Tightening torque:

25 N·m (2.5 kgf-m, 18.4 ft-lb)

(3) Fit the plug to service hole.

11. Install the power steering pump.

(1) Install the power steering pump.

Tightening torque:

Refer to “COMPONENT” of “Power Steering” for the tightening torque.

(2) Connect the power steering pump switch connector.

(3) Install and adjust the front side belt.

12. Lift up the vehicle.

13. Tighten the bolts and nuts which hold lower side of the transmission to engine.

Tightening torque:

50 N·m (5.1 kgf-m, 36.9 ft-lb)

AT model

MT model

14. Tighten the nuts which install the engine mounting onto the crossmember.

NOTE:

Make sure that the engine mounting nuts (A) and locator (B) are securely installed.

Tightening torque:

85 N·m (8.7 kgf-m, 62.7 ft-lb)

15. Install the joint pipe and front exhaust pipe.

16. Install the turbocharger.

17. Install the center exhaust pipe.

18. Connect the ground cable.

Tightening torque:

7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

19. Lower the vehicle.

20. Connect the following hoses.

(1) Fuel delivery hose and fuel return hose

Tightening torque:

1.25 N·m (0.1 kgf-m, 0.9 ft-lb)

(2) Evaporation hose

(3) Heater inlet and outlet hoses

(4) Brake booster vacuum hose

21. Connect the following connectors and terminals.

(1) Engine harness connectors

(2) Generator connector and terminal

Tightening torque:

15 N·m (1.5 kgf-m, 11.1 ft-lb)

(3) A/C compressor connector

(4) Secondary air pump connector

22. Install the intercooler.

23. Install the A/C pressure hoses.

24. Install the radiator.

25. Install the coolant filler tank.

26. Install the air cleaner case and air intake duct.

27. Install the battery.

28. Fill engine coolant.

29. Charge the A/C system with refrigerant.

30. Check the ATF level and replenish it if necessary. (AT model)

31. Install the collector cover.

32. Change the bolt mounting position from (B) to (A), and close the front hood.

Tightening torque:

7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

33. Lower the vehicle from lift.