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.

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)

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. Install the starter.

9. Install the power steering pump.

(1) Install the power steering pump to the engine.

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.

10. Lift up the vehicle.

11. Attach 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)

12. Attach the nuts which secure the engine mount to 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)

13. Connect the ground cable.

Tightening torque:

7.5 N·m (0.8 kgf-m, 5.5 ft-lb)

14. Install the joint pipe and front exhaust pipe.

15. Install the turbocharger.

16. Install the center exhaust pipe.

17. 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 hose and heater outlet hose

(4) Brake booster vacuum hose

18. Connect the following connectors and terminals.

(1) Generator connector and terminal

Tightening torque:

15 N·m (1.5 kgf-m, 11.1 ft-lb)

(2) A/C compressor connector

(3) Secondary air pump connector

19. Install the engine harness connector to engine harness bracket, then connect the bulkhead harness connector to the engine harness connector.

• LHD model

• RHD model

20. Install the intercooler.

21. Connect the A/C pressure hoses to A/C compressor.

22. Install the radiator.

23. Install the coolant filler tank.

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

25. Install the battery.

26. Fill engine coolant.

27. Charge the A/C system with refrigerant.

28. Install the V-belt cover.

Tightening torque:

13 N·m (1.3 kgf-m, 9.6 ft-lb)

29. 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)