ekk2.pdf

HASPORT PERFORMANCE

Installation Instructions For:

Part Number EKK2

1996-2000 Honda Civic with EG or DC cross member, lower control arms and steering rack

HASPORT PERFORMANCE Inc.

2849 South 44 th St. Phoenix, AZ 85040

Phone: (602) 470-0065 Fax: (602) 470-0516

www.hasport.com

Hasport Performance mounts are the result of extensive research and engineering. All mounts are designed with up to date solid modeling software. Each mount is

constructed of lightweight 6061-T6-billet aluminum and CNC machined in our state-of-art machining facility. Hasport Performance motor mounts control engine

movement, transferring more power to the wheels. All mounts have a lifetime warranty against any defects.

Right-hand Mount

Rear Mount

Left-hand Mount

Right-hand Hardware

Left-hand Hardware

Rear Hardware

Qty

Description

Qty

Description

Qty

Description

12 x 1.25 x 120 Hex

12 x 1.25 x 30 Hex

10 x 1.25 x 40 Hex

12 x 1.25 Lock Nut

12 x 1.25 x 50 Hex

10 x 1.25 x 50 Hex

12mm Flat Washers

12 x 1.25 x 120 Hex

10mm Flat Washers

12 x 1.25 Lock Nut

12 x 1.25 x 50 Hex

12mm Flat Washers

12 x 1.25 x 70 Hex

12 x 1.25 x 100 Hex

12 x 1.25 Lock Nut

Right-hand Bracket

Rear Bracket

Left-hand Bracket

Tools Required

1. Metric Socket set 8mm – 19mm

2. 32mm Socket

3. 3/8” Short, Medium & Long Extension

4. 10mm Line Wrench

5. 10mm, 12mm, 14mm, 17mm, 19mm & 22mm Open-end Wrenches

6. Die Grinder with Cut-off Wheel or Sawzall

7. Hammer

8. Pry-bar

9. Roll-Pin Punch Set

10. Spot Drill

11. Drill

12. Needle-Nose Pliers

13. Hose-Clamp Pliers

14. Sharpie Marker

15. Stud Extractor

12mm Flat Washers

Additional Recommended Items

Automotive Lift

Factory Service Manuals for 1996-2000 Civic and 2002 RSX

(Available from www.helminc.com or Honda/Acura Dealers)

Patience

Please read all instructions before proceeding with the installation

These instructions pertain ONLY to the ENGINE MOUNTING of a K-Series Motor into an EK civic chassis.

If you are installing a K24, you will need to purchase an additional engine bracket from Honda. This bracket is needed in-order for the right-mount to properly bolt up

to the K24 motor. Honda Part #: 11910-PPA-000

A general list of parts needed for the K-Series swap in the 1996-00 Civic is listed below

Quantity

Description

Hasport EKK2 Bolt In Mount Kit (This Kit)

K20A Intermediate Shaft

Hasport EKKAX Axle Set

K20A or K24 Motor and Transmission

Hasport EKKWH Conversion Harness

K-Series ECU with Immobilizer removed

RSX Shifter Box & Cables (Hasport Shifter Box Under Construction)

RSX Throttle Cable or Hasport EKKTC Throttle Cable

Custom Header, Exhaust & Catalytic Converter

K20 After-market Fuel Rail With Return Line Option & Regulator or External Fuel Pressure Regulator with return port and stock fuel rail

RSX Brake Booster Hose

2002 Civic Si Radiator Hoses (RSX or Si Radiator Applications)

EG or DC cross member with steering rack and lower control arms (PS racks must be use with PS cross members)

Removing The Engine: (Save all Bolts, You will Need Most of Them!)

1. Discharge R134A from AC system. (Have a professional evacuate your system.)

2. Place the car on a lift or on jack-stands. (Jack Optional)

3. Disconnect the negative and positive battery cables and remove the battery, with battery tray, and the 10mm bolts connecting the engine harness

to the chassis. (10mm Socket)

4. Disconnect ECU from engine harness and pull ECU connectors through the firewall, clearing the harness from the chassis. (10mm Wrench)

5. Disconnect engine harness from drivers side shock-tower. (No Tools Needed)

6. Disconnect positive battery cable from starter and remove alternator cables from under hood fuse box.

7. Drain the fluids: Oil, Transmission, Radiator & Clutch (17mm Wrench, 3/8” Ratchet 10mm Line Wrench)

8. Remove shift knob from shifter. (No Tools Required)

9. Remove the lug nuts & wheels (19mm Socket & Impact Wrench)

10. Remove the left and right shock forks. (17mm, 14mm Socket & 17mm Wrench)

11. Disconnect left & right lower ball joints (17mm Socket, Ball Joint Tool, Hammer)

12. Remove CV-axles (32mm Socket, Impact Wrench & Pry-bar)

13. Remove shift linkage (Roll-pin Punch, Hammer, Extension, 12mm Socket & 12mm Wrench)

14. Remove a-pipe & catalytic converter (14mm socket, 12mm & 14mm Wrench)

15. Remove radiator with fan assembly. (10mm Socket & Hose-clamp pliers)

16. Remove heater hoses. (Hose Clamp Pliers)

17. Remove the clutch slave cylinder line connecting it to the master cylinder. (10mm Line Wrench, 12mm Socket)

18. Remove AC system: AC lines, compressor, condenser and fan. (10mm Socket)

19. Remove AC bracket and under-frame-rail mount (14mm Socket & Extension)

20. Remove transmission under-frame-rail mount and bracket. (14mm, 17mm Socket & Extension)

21. Remove fuel line & fuel return line. (22mm or 17mm Socket & Needle-Nose pliers)

22. Remove throttle cable. (12mm Wrench)

23. Remove brake booster hose from motor. (Needle-Nose Pliers)

24. Remove cruise control unit & cable (optional). (10mm Socket & 12mm Wrench)

25. Remove any additional connections that attach the motor to the chassis.

26. Secure the motor on a stand or engine hoist. (Roller Cart, Engine Hoist)

27. Remove the rear engine bracket. (17mm, 19mm Socket)

28. Remove left mount. (14mm & 17mm Socket)

29. Remove right mount. (14mm & 17mm Socket)

30. Remove motor from car and remaining rear engine mount. If you have a lift, raise the vehicle off the engine. If you have an Engine Hoist pull

the motor out of the engine bay. (14mm Socket & Lift or Hoist)

31. Remove the cross member, lower control arms and steering rack and replace them with ones from a 92-95 Civic or the similar 94-01 Integra. If

you use a power steering rack you will need a power steering cross member too. In order for power steering to work with you new K-series motor

custom power steering lines will need to be made.

Preparing The Engine Bay

1. Using the hardware provided,

bolt rear mount to cross-

member.

(14mm or 17mm Wrench)

Bolt the left bracket to the

drivers’ side frame-rail, using

existing mount hardware.

(14mm Socket)

3. Bolt the right bracket to the

passenger side frame-rail using

the stock hardware. (17mm

Socket)

You will need to relocate the

stock radiator if you wish to

use that with the new K-series

engine. Either a stock radiator

moved to the left side of the

car, or an EP3 radiator is

usually used

. To remove the lower mounting

brackets you can drill the spot welds

out using a bullet point 3/8ths inch

drill bit or spot weld removal bit. The

brackets can then be reattached into a

new location to go with the new

radiator setup.

Preparing The Motor

1. Connect the Hasport wiring

conversion harness to all of the

proper connections on the

motor. Leave the ECU Plugs

on top of valve cover at this

time. (No Tools Needed)

Remove the two studs on the

transmission, where the

Hasport mount will be used.

(Stud extractor)

Installing the Motor

1. The EKK2 mount kit features

dual mounting holes in each

bracket. By using the top

holes, the kit is designed to

give maximum clearance to

K20 engines. You can also use

these holes to mount the K24

engine, but you will need to

modify the hood for clearance.

Typically that means removing

some of the inner support

structure.

If you don’t want to modify the hood

you can simply use the lower mount

holes.

Depending on how you are

installing the engine, you may

be able to go ahead and hang

the rear bracket from the rear

mount. If this makes the

engine bay too tight, you can

install it as the engine is being

lowered into place. Use the

long 12mm bolt to hold the

bracket on the mount. Make

sure you use the proper hole

for the engine height. (No

tools)

If you are using the top mount holes

on the side mounts for the higher

mount position, you will use the

lower mount hole on the rear

bracket. This due to the fact that

the left and right brackets mount to

the chassis and the rear bracket

mounts to the engine.

3. If you have an engine hoist,

lower the engine and

transmission assembly into

engine bay. If you are

performing the swap on a lift,

place engine and transmission

assembly onto the engine stand

and lower the car onto the

motor as depicted below.

(Engine Hoist or Lift & Engine

Stand)

Place the left-mount on the

top of the transmission and

insert the 12mm bolts and

washers, supplied in the left-

mount hardware bag. Snug

the 12mm bolts down to the

transmission but do not fully

tighten them until all three

mounts are in place. (19mm

Socket)

5. Once the mount is lined up

with the bracket, use the 12mm

X 120mm bolt, 12mm locknut

& 2-12mm flat washers,

supplied in the left-mount

hardware bag, attach the mount

to the bracket. Do not fully

tighten at this time. (19mm

Socket, 19mm Wrench Hoist)

Place the right-mount over

the studs on the motor’s right-

hand engine bracket. Install

the stock 12mm flange nut

onto the tall stud and the

supplied 12mm locknut and

washer onto the short stud.

Snug the 12mm locknut and

flange nut down to the

bracket but do not fully

tighten until the other mounts

are in place. (17mm &

19mm Socket)

7. Raise the motor or lower the

car so the right mount’s bolt

hole lines up with the right-

bracket’s through hole. Using

the 12mm X 120mm bolt,

12mm locknut & 2-12mm flat

washers, supplied in the right-

mount hardware bag, attach the

mount to the bracket. Snug the

12mm locknut down to the

12mm through-bolt but do not

tighten until the other mounts

are in place. (19mm Socket &

19mm Wrench)

For information purposes, this

picture shows how the rear

bracket will attach to the

transmission. Connect it to

the engine by first putting the

top bolt in finger tight. Then

the two bottom bolts can be

installed and all tightened.

You may need to lift the

differential case of the engine

to line up the bottom bolts.

9. Torque all mount and bracket

bolts according to

specifications below. (14mm,

17mm, 19mm Socket &

17mm, 19mm Wrench)

Mount / Bracket

(lbf*ft)

10.

Run engine harness through

the firewall to the ECU and

use the boot from the stock

EK engine harness to attach

the harness to the firewall.

(10mm Socket)

Hasport Mounts to

Brackets

Left Mount to

Transmission

Left Bracket to Frame Rail

Right Mount to Engine

Bracket

Right Bracket to Frame

Rail

Rear Mount to

Transmission

11. Install battery tray and battery.

(10mm, 12mm Socket)

12.

Install RSX shifter cables on

the transmission. Route the

shifter cables into the Civics’

cabin by cutting a small hole

in the floor in front of the old

shifter location. (Needle-

Nose Pliers & Die Grinder

with Cutoff Wheel)

13. Install the left and right Hasport EGKAX axles, put the suspension back

together and the wheels on the car. (14mm, 17mm, 19mm, 32mm Socket

& 17mm Wrench)

14. Congratulations! Hopefully, you have just successfully completed the

K-series engine installation into your 1996-2000 Honda Civic. With the

NEW EKK2 kit the engine will sit about two inches further rearward

than the same engine with an EKK1 kit and you will gain ground

clearance too. Additional information & tips pertaining to installing the

accessory systems for the K-Series swap in an EK Civic can be obtained

online at www.hasport.com .

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