Installation
1. Attach lifting cables to the engine lifting eyes on the engine and remove any stack in the cables.2. Remove the engine from the engine stand.
3. Install the flywheel.
4. Connect the engine and transaxle. Tighten the engine-to-transaxle (A) bolts and transaxle-to-engine (B) bolts as shown.
5. Lower the engine and transaxle assembly into the engine compartment.
6. Install the rear transaxle support insulator and tighten the three rear transaxle support insulator nuts to 67-93 Nm (50-68 ft. lbs.). Tighten the rear transaxle support insulator through bolt to 86-116 Nm (63-86 ft. lbs.).
7. Install the LH transaxle support insulator and tighten the LH transaxle support insulator nuts to 75-104 Nm (55-77 ft. lbs.). Tighten the LH transaxle support insulator through bolt to 86-116 Nm (63-86 ft. lbs.).
8. Install the RH engine support insulator and tighten the two RH engine support insulator nuts to 74-103 Nm (54-76 ft. lbs.). Tighten the RH engine support insulator through bolt to 67-93 Nm (50-68 ft. lbs.).
9. Remove the engine lifting cables.
10. Raise and support the vehicle.
11. Install the power steering pump. Tighten the three power steering pump bolts to 31-46 Nm (23-34 ft. lbs.).
12. Tighten the power steering pump rear bracket bolt to 32-46 Nm (24-33 ft. lbs.).
13. Position the drive belt over the water pump pulley and power steering pump pulley.
14. If equipped, install the A/C compressor. Tighten the A/C compressor bolts to 38-51 Nm (28-38 ft. lbs.).
15. Position the drive belt over the generator pulley, crankshaft pulley and A/C clutch pulley.
16. Install the control rod to support bar stud nut. Tighten the control rod to support bar stud nut to 32-46 Nm (23-33 ft. lbs.).
17. Install the transmission selector shift rod adjustment sleeve. Tighten the transmission selector shift rod adjustment sleeve to 16-22 Nm (12-16 ft. lbs.).
18. Install both front wheel driveshaft and joints.
19. Install the transmission support crossmember. Tighten the six rear engine support nuts and two bolts as shown.
20. Align the exhaust inlet pipes on the front and rear exhaust manifolds and install the exhaust manifold nuts.
21. Tighten the exhaust inlet pipe nuts to 40-55 Nm (30-41 ft. lbs.).
22. Connect the heated oxygen sensor (H02S) electrical connectors.
23. Install the crossmember. Tighten the crossmember bolts to 94-126 Nm (69-93 ft. lbs.).
24. Install the front fender splash shields. Tighten the front fender splash shield bolts to 8-1O Nm (71 -88 inch lbs.).
25. Install the wheel and tire assemblies. Tighten the lug nuts to 88-118 Nm (65-87 ft. lbs.).
26. Lower the vehicle.
27. Install the bolt retaining the power steering hose bracket to the power steering pump, located on the top of the power steering pump.
28. Connect the KS electrical connector.
29. Connect the ECT sensor electrical connector and the water temperature indicator sender unit electrical connector to the front water hose connection.
30. Connect the crankshaft position (CKP) sensor electrical connector.
31. Connect the climate control assembly vacuum hose to the intake manifold.
32. Connect the vacuum hoses and the electrical connectors to the EGR solenoid vacuum valve and EGR valve.
33. Connect the EGR valve position sensor electrical connector.
34. Connect the VSS electrical connector.
35. Install the transaxle ground, located at the top rear of the transaxle.
36. Connect the backup lamp switch electrical connector.
37. Install the ground wire bracket-to-rear transaxle support insulator harness bracket bolt located near the starter.
38. Connect the fuel injection supply manifold electrical connectors.
39. Connect the TP sensor electrical connector.
40. Connect the two electrical connectors to the top of the distributor.
41. Connect the PNP switch electrical connector.
42. Connect the starter terminals.
43. Connect the heater water hoses.
44. Connect the fuel supply tube to the fuel injection supply manifold. Tighten the two fuel tube bracket bolts to 8-10 Nm (71-88 inch lbs.) and the fuel supply tube bolt to 25-34 Nm (18-25 ft. lbs.).
45. Connect the return fuel tube and vacuum hose to the fuel pressure regulator.
46. Install the fuel filter in the bracket and install the two fuel filter bracket nuts. Tighten the fuel filter bracket nuts to 8-10 Nm (71-88 inch lbs.).
47. If equipped, install the speed control servo, tighten the speed control servo nuts and connect the electrical connector.
48. Connect the vacuum hose to the speed control servo.
49. Connect the vacuum hoses to the throttle body.
50. Connect the brake vacuum booster hose.
51. Connect the IAC BPA valve electrical connector.
52. Connect the A/C and generator wiring harness bracket to the front of the cylinder block.
53. Connect the oil pressure switch electrical connector.
54. If equipped, connect the A/C compressor electrical connector.
55. Connect the generator electrical connectors.
56. Install the battery tray and bolts.
57. Connect the accelerator cable to the throttle body.
58. Connect the lower clutch slave cylinder tube to the clutch slave cylinder and then install the two clips.
59. Position the radiator with the fan shroud into the vehicle and tighten the two radiator hold-down bolts to 8-10 Nm (71-88 inch lbs.).
60. Connect the two engine cooling fan motor electrical connectors.
61. Install the upper radiator hose, the lower radiator hose, and the radiator coolant recovery reservoir overflow hose. Tighten all the hose clamps.
62. Install the rear transaxle support insulator harness bracket bolt. Tighten the rear transaxle support insulator harness bracket bolt securely.
63. Install the engine air cleaner. Connect all vacuum and electrical connectors.
64. Install and connect the battery.
65. Refill the engine with specified engine oil, if necessary.
66. Bleed the clutch hydraulic system.
67. Refill the cooling system with the specified type and mixture of antifreeze and water.
68. Start the engine and check for leaks and proper operation.
69. Stop the engine and check all fluid levels. Refill as necessary.