ENGINE ASSEMBLY INSTALLATION
CAUTION / NOTICE / HINT
As the engine assembly with transaxle is extremely heavy, the engine lifter may suddenly drop if the instructions listed in the repair manual are not followed. Therefore, always follow the instructions listed in the repair manual when performing this procedure.
for Manual Transaxle:
When the transaxle is removed, be sure to use a new clutch release with bearing cylinder assembly and new installation bolts. Removal of the transaxle allows the compressed clutch release with bearing cylinder assembly to return to its original position, and dust could damage the seal of the clutch release with bearing cylinder assembly, possibly causing clutch fluid leaks.
Perform "Inspection After Repairs" after replacing the engine assembly, cylinder head sub-assembly, camshaft, No. 2 camshaft, camshaft timing gear assembly, camshaft timing exhaust gear assembly, piston sub-assembly or piston ring.
for K111, K111F:
except K111, K111F:
PROCEDURE
INSTALL ENGINE MOUNTING INSULATOR LH
Tip:Perform this procedure only when replacement of the engine mounting insulator is necessary.
-
Temporarily install the engine mounting insulator LH with the 4 bolts.
Tighten the 4 bolts in the sequence shown in the illustration.
95 N*m
969 kgf*cm
70 ft.*lbf
Install the wire harness clamp bracket with the bolt.
7.7 N*m
79 kgf*cm
68 in.*lbf
-
INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH
Tip:Perform this procedure only when replacement of the engine mounting insulator is necessary.
-
Temporarily install the engine mounting insulator sub-assembly RH with the 3 bolts.
Tighten the 3 bolts in the sequence shown in the illustration.
95 N*m
969 kgf*cm
70 ft.*lbf
Install the radiator reservoir bracket with the bolt.
5.0 N*m
51 kgf*cm
44 in.*lbf
-
INSTALL REAR ENGINE MOUNTING INSULATOR
Tip:Perform this procedure only when replacement of the rear engine mounting insulator is necessary.
Temporarily install the rear engine mounting insulator with the 2 bolts and 2 nuts.
*A
for 2WD
*B
for 4WD / AWD
*C
for Manual Transaxle
*D
for CVT
Tighten the 2 bolts and 2 nuts in the sequence shown in the illustration.
95 N*m
969 kgf*cm
70 ft.*lbf
INSTALL DRIVE SHAFT BEARING BRACKET
Install the drive shaft bearing bracket with the 3 bolts.
64 N*m
653 kgf*cm
47 ft.*lbf
INSTALL ENGINE HANGER
REMOVE ENGINE FROM ENGINE STAND
Note:Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.
With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.
Attach an engine sling device and hang the engine with a chain block.
Lift the engine and remove it from the engine stand.
FIX ENGINE ASSEMBLY
INSTALL ENGINE WIRE
Install the engine wire to the engine.
INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)
INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY (for Manual Transaxle)
INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Manual Transaxle)
INSTALL CLUTCH TUBE (for Manual Transaxle)
INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)
INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)
INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transaxle)
INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for CVT)
INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)
for 2WD
for 4WD/AWD
INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY (for CVT)
for 2WD
for 4WD/AWD
INSTALL TRANSFER ASSEMBLY (for 4WD/AWD)
INSTALL FLYWHEEL HOUSING SIDE COVER
INSTALL STARTER ASSEMBLY
for 1.0 kW
for 1.3 kW
INSTALL STEERING GEAR HEAT INSULATOR (for RHD)
INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
Temporarily install the front engine mounting insulator with the through bolt and nut.
-
*1
Alignment Mark
*2
Protrusion
Temporarily install the front suspension crossmember with the through bolt.
Tip:When installing the suspension crossmember, align the protrusion of the engine mounting bracket with the alignment mark of the engine mounting insulator.
Place the engine on an engine lifter.
Tip:Place the engine on wooden blocks or equivalent so that the engine is level.
Operate the engine lifter and install the engine to the vehicle.
CAUTION:Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.
Note:Make sure that the engine is clear of all wiring and hoses.
While raising the engine into the vehicle, do not allow it to contact the vehicle.
Temporarily install the front suspension crossmember with the 2 bolts.
Temporarily install the front suspension member brace rear RH and LH with the 6 bolts.
Install the engine mounting insulator LH with the through bolt and nut.
56 N*m
571 kgf*cm
41 ft.*lbf
Note:While holding the bolt in place, tighten the nut.
-
Install the engine mounting insulator RH with the bolt and 2 nuts.
for bolt and nut A
95 N*m
969 kgf*cm
70 ft.*lbf
for nut B
52 N*m
530 kgf*cm
38 ft.*lbf
Tighten the 2 front suspension crossmember sub-assembly bolts.
137 N*m
1397 kgf*cm
101 ft.*lbf
-
Bolt A
Bolt B
Tighten the 6 front suspension member brace rear bolts.
for bolt A
137 N*m
1397 kgf*cm
101 ft.*lbf
for bolt B
93 N*m
948 kgf*cm
69 ft.*lbf
Remove the 2 bolts and No. 1 and No. 2 engine hangers.
Install the air fuel ratio sensor bracket with the bolt. Then connect the air fuel ratio sensor connector.
39 N*m
398 kgf*cm
29 ft.*lbf
Attach the fuel tube clamp.
-
Bolt A
Bolt B
Install the front crossmember sub-assembly with the 6 bolts.
for bolt A
99 N*m
1010 kgf*cm
73 ft.*lbf
for bolt B
95 N*m
969 kgf*cm
70 ft.*lbf
Tighten the through bolt of the rear engine mounting insulator.
95 N*m
969 kgf*cm
70 ft.*lbf
Tip:Check that the protrusion of the engine mounting bracket is aligned with the alignment mark of the engine mounting insulator.
Tighten the through bolt and nut of the front engine mounting insulator.
145 N*m
1479 kgf*cm
107 ft.*lbf
Note:While holding the nut in place, tighten the through bolt.
INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH
Install the front suspension member reinforcement LH with the 4 bolts.
99 N*m
1010 kgf*cm
73 ft.*lbf
INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH
-
Install the front suspension member reinforcement RH with the 4 bolts.
99 N*m
1010 kgf*cm
73 ft.*lbf
-
INSTALL FRONT LOWER ENGINE MOUNTING BRACKET REINFORCEMENT (for 2WD)
-
Install the front lower engine mounting bracket reinforcement with the 2 bolts.
99 N*m
1010 kgf*cm
73 ft.*lbf
-
INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT (for CVT)
for 2WD
for 4WD/AWD
TEMPORARILY INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD/AWD)
TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD/AWD)
CONNECT HEATED OXYGEN SENSOR (for 4WD/AWD)
INSTALL FRONT EXHAUST PIPE ASSEMBLY
INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
for 2WD
for 4WD/AWD
INSTALL FRONT DRIVE SHAFT HOLE SNAP RING
INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
for 2WD
for 4WD/AWD
CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH
CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH
Tip:Use the same procedure described for the LH side.
CONNECT TIE ROD END SUB-ASSEMBLY LH
CONNECT TIE ROD END SUB-ASSEMBLY RH
Tip:Use the same procedure described for the LH side.
CONNECT FRONT STABILIZER LINK ASSEMBLY LH
CONNECT FRONT STABILIZER LINK ASSEMBLY RH
Tip:Use the same procedure described for the LH side.
CONNECT FRONT SPEED SENSOR LH
CONNECT FRONT SPEED SENSOR RH
Tip:Use the same procedure described for the LH side.
INSTALL FRONT AXLE SHAFT NUT LH
INSTALL FRONT AXLE SHAFT NUT RH
Tip:Use the same procedure described for the LH side.
CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY
CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY
INSTALL COLUMN HOLE COVER SILENCER SHEET
CONNECT CLUTCH HOSE (for Manual Transaxle)
Connect the clutch hose and install a new clip to the clutch hose.
Note:Install the clip as far as it will go.
Using a 10 mm union nut wrench, connect the clutch hose to the accumulator to flexible hose tube while holding the flexible hose.
15 N*m
153 kgf*cm
11 ft.*lbf
Note:Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench.
Do not kink or damage the clutch release cylinder tube.
Do not allow any foreign matter such as dirt or dust to enter the clutch release cylinder tube from the clip or bracket.
This torque value is effective when the union nut wrench is parallel to the torque wrench.
CONNECT TRANSAXLE CONTROL CABLE ASSEMBLY (for CVT)
Connect the clamp of the transaxle control cable assembly with the bolt.
5.0 N*m
51 kgf*cm
44 in.*lbf
Connect the transaxle control cable assembly to the control cable support.
Connect the transaxle control cable assembly to the bracket with a new clip.
Connect the transaxle control cable assembly to the control shaft lever with the nut.
12 N*m
122 kgf*cm
9 ft.*lbf
CONNECT TRANSAXLE CONTROL CABLE ASSEMBLY (for Manual Transaxle)
Connect the transaxle control cable assembly to the control cable bracket and install 2 new clips.
Connect the transaxle control cable assembly to the transaxle and install the 2 clips.
CONNECT WIRE HARNESS AND HOSE
Connect the heater water outlet hose and heater water inlet hose to the heater core and slide the 2 clamps to secure the hoses.
Connect the connector tube hose to the air tube and slide the clamp to secure it.
for Manual Transaxle:
Attach the clamp and connect the engine wire to the manual transaxle with the bolt.
19 N*m
194 kgf*cm
14 ft.*lbf
for CVT:
Attach the clamp and connect the engine wire to the CVT with the bolt.
8.4 N*m
86 kgf*cm
74 in.*lbf
Attach the wire harness clamp.
Connect the starter wire with the nut, and then connect the terminal cap.
9.8 N*m
100 kgf*cm
87 in.*lbf
Attach the 2 claws to install the wire harness to the engine room No. 1 junction block.
Connect the 2 wire harness connectors to the engine room No. 1 junction block and install the nut.
12.8 N*m
131 kgf*cm
9 ft.*lbf
Attach the 2 clamps and install the bolt.
8.4 N*m
86 kgf*cm
74 in.*lbf
CONNECT FUEL TUBE SUB-ASSEMBLY
Connect the fuel tube sub-assembly and then install the No. 1 fuel pipe clamp.
CONNECT NO. 1 RADIATOR HOSE
for CVT:
Connect the breather plug hose to the clamp.
Connect the No. 1 radiator hose to the cylinder head and slide the clamp to secure it.
INSTALL ECM
INSTALL BATTERY BRACKET REINFORCEMENT
INSTALL FRONT BATTERY BRACKET
CONNECT RADIATOR HOSE SUB-ASSEMBLY
INSTALL BATTERY TRAY
INSTALL BATTERY
INSTALL BATTERY CLAMP SUB-ASSEMBLY
INSTALL AIR CLEANER CASE SUB-ASSEMBLY
INSTALL AIR CLEANER CAP SUB-ASSEMBLY
CONNECT COMPRESSOR WITH PULLEY ASSEMBLY
Using an E8 "TORX" socket wrench, connect the compressor with pulley assembly with the 2 stud bolts.
9.8 N*m
100 kgf*cm
87 in.*lbf
-
Install the 2 bolts and 2 nuts.
25 N*m
255 kgf*cm
18 ft.*lbf
Tip:Tighten the bolts and nuts in the order shown in the illustration.
Connect the connector.
CONNECT NO. 2 RADIATOR HOSE
Connect the No. 2 radiator hose to the water inlet and slide the clamp to secure it.
INSTALL GENERATOR ASSEMBLY
for 100 A Type:
for 130 A Type:
INSTALL V-RIBBED BELT
ADJUST V-RIBBED BELT
CONNECT RADIATOR RESERVOIR ASSEMBLY
Connect the radiator reservoir assembly with the 2 bolts.
5.0 N*m
51 kgf*cm
44 in.*lbf
Connect the No. 1 and No. 2 water by-pass hoses to the radiator reservoir assembly and slide the 2 clamps to secure the hoses.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Note:When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
ADD MANUAL TRANSAXLE OIL (for Manual Transaxle)
for 2WD
for 4WD/AWD
ADD ENGINE COOLANT
ADD ENGINE OIL
ADD TRANSFER OIL (for 4WD / AWD)
ADD CONTINUOUSLY VARIABLE TRANSAXLE FLUID (for CVT)
for 2WD
for 4WD/AWD
INSPECT SHIFT LEVER POSITION (for CVT)
INSPECT FOR FUEL LEAK
INSPECT FOR COOLANT LEAK
INSPECT FOR OIL LEAK
INSPECT FOR EXHAUST GAS LEAK
INSPECT V-RIBBED BELT
INSPECT IGNITION TIMING
INSPECT ENGINE IDLE SPEED
INSPECT CO/HC
ADJUST FRONT WHEEL ALIGNMENT
INSTALL NO. 2 ENGINE UNDER COVER (w/ Cover)
Install the No. 2 engine under cover with the bolt and clip.
5.5 N*m
56 kgf*cm
49 in.*lbf
INSTALL FRONT FLOOR COVER (w/ Cover)
INSTALL REAR ENGINE UNDER COVER RH
Install the rear engine under cover RH with the 3 clips.
INSTALL REAR ENGINE UNDER COVER LH
Install the rear engine under cover LH with the 3 clips.
INSTALL NO. 1 ENGINE UNDER COVER
INSTALL NO. 2 CYLINDER HEAD COVER
RESET MEMORY
for 2WD
for 4WD/AWD