Engine Assembly: Installation

1. Remove the release bearing from clutch cover with flat type screw driver.
   Fig 1: Removing Release Bearing From Clutch Cover With Flat Type Screw Driver

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2. Install the release bearing on transmission.
3. Install the release fork into release bearing tab.
   Fig 2: Installing Release Fork Into Release Bearing Tab

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4. Apply grease to the specified points.
   • Spline FX2200
   • Shaft SUNLIGHT 2
     Fig 3: Identifying Shaft Sunlight 2

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5. Insert the release fork shaft into release fork.
   CAUTION: Make sure the cutout portion of release fork shaft contacts spring pin. 
   Fig 4: Inserting Release Fork Shaft Into Release Fork

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6. Tighten the plug.

   Tightening torque: 

   44 N.m (4.5 kgf-m, 32.5 ft-lb) 

   Fig 5: Tightening Plug

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Tightening torque: 

34 N.m (3.5 kgf-m, 25.3 ft-lb) 

1. Position the engine in engine compartment, and then align it with the transmission.
   NOTE: Be careful not to damage the adjacent parts or body panels with crank pulley, oil pressure gauge, etc.
2. Apply a small amount of grease to the splines of mainshaft. (MT model)

Tightening torque: 

50 N.m (5.1 kgf-m, 36.9 ft-lb) 

Fig 6: Tightening Bolts Which Hold Right Upper Side Of Transmission To Engine

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Tightening torque: 

T1: 50 N.m (5.1 kgf-m, 37 ft-lb) 

T2: 58 N.m (5.9 kgf-m, 43 ft-lb) 

Fig 8: Installing Pitching Stopper

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ST 498277200 STOPPER SET

1. Tighten bolts which hold torque converter clutch to drive plate.
2. Tighten other bolts while rotating the engine by using socket wrench.
   CAUTION: Be careful not to drop bolts into torque converter clutch housing. 

   Tightening torque: 

   25 N.m (2.5 kgf-m, 18.1 ft-lb) 

   Fig 9: Tightening Other Bolts While Rotating Engine By Using Socket Wrench

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3. Clog plug onto service hole.

1. Install the power steering tank on bracket.
   Fig 11: Installing Power Steering Pump On Bracket

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2. Install the power steering pump.

   Tightening torque: 

   20.1 N.m (2.05 kgf-m, 14.8 ft-lb) 

   Fig 12: Installing Power Steering Pump

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3. Install the power steering pipe bracket on intake manifold RH.
   Fig 13: Installing Power Steering Pipe Bracket On Intake Manifold RH

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4. Connect the power steering switch connector.
   Fig 14: Connecting Power Steering Switch Connector

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5. Install the front side V-belt, and adjust it. Refer to V-BELT .

Tightening torque: 

50 N.m (5.1 kgf-m, 36.9 ft-lb) 

Fig 15: Tightening Nuts Which Hold Lower Side Of Transmission To Engine

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Tightening torque: 

83 N.m (8.5 kgf-m, 61 ft-lb) 

Fig 16: Tightening Nuts Which Install Front Cushion Rubber Onto Crossmember

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1. Fuel delivery hose, return hose and evaporation hose
2. Heater inlet and outlet hoses
3. Brake booster vacuum hose

1. Engine ground terminal
2. Engine harness connectors
3. Generator connector and terminal
4. A/C compressor connectors

1. Accelerator cable
2. Clutch release spring

1. Install the intercooler. Refer to INSTALLATION , Intercooler.
2. Install the air cleaner element and air cleaner upper cover.
3. Install the engine harness connector bracket.
4. Install the filler hose to air cleaner case.

Tightening torque: 

25 N.m (2.5 kgf-m, 18.1 ft-lb) 

Fig 17: Installing A/C Pressure Hoses

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Refer to REPLACEMENT Engine Coolant.

Refer to REFRIGERANT CHARGING PROCEDURE .