ekk2, AUTO WARSZTAT, E-book - Honda
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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
1
12 x 1.25 x 120 Hex
1
12 x 1.25 x 30 Hex
2
10 x 1.25 x 40 Hex
3
12 x 1.25 Lock Nut
2
12 x 1.25 x 50 Hex
1
10 x 1.25 x 50 Hex
4
12mm Flat Washers
1
12 x 1.25 x 120 Hex
3
10mm Flat Washers
1
12 x 1.25 Lock Nut
1
12 x 1.25 x 50 Hex
5
12mm Flat Washers
2
12 x 1.25 x 70 Hex
1
12 x 1.25 x 100 Hex
1
12 x 1.25 Lock Nut
Right-hand Bracket
5
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
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
1
Hasport EKK2 Bolt In Mount Kit (This Kit)
1
K20A Intermediate Shaft
1
Hasport EKKAX Axle Set
1
K20A or K24 Motor and Transmission
1
Hasport EKKWH Conversion Harness
1
K-Series ECU with Immobilizer removed
1
RSX Shifter Box & Cables (Hasport Shifter Box Under Construction)
1
RSX Throttle Cable or Hasport EKKTC Throttle Cable
1
Custom Header, Exhaust & Catalytic Converter
1
K20 After-market Fuel Rail With Return Line Option & Regulator or External Fuel Pressure Regulator with return port and stock fuel rail
1
RSX Brake Booster Hose
1
2002 Civic Si Radiator Hoses (RSX or Si Radiator Applications)
1
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.
2
Preparing The Engine Bay
1. Using the hardware provided,
bolt rear mount to cross-
member.
(14mm or 17mm Wrench)
2.
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)
4.
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)
2.
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.
2.
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)
4.
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)
3
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)
6.
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)
8.
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
47
Left Mount to
Transmission
40
Left Bracket to Frame Rail
33
Right Mount to Engine
Bracket
40
Right Bracket to Frame
Rail
43
Rear Mount to
Transmission
47
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
4
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