ENGINE ASSEMBLY INSTALLATION
CAUTION / NOTICE / HINT
When the manual transaxle assembly is removed, be sure to use a new clutch release with bearing cylinder and new installation bolts. Removal of the manual transaxle assembly allows the compressed clutch release with bearing cylinder to return to its original position, and dust from the moving section could damage the seal of the clutch release with bearing cylinder, possibly causing clutch fluid leaks.
PROCEDURE
INSTALL ENGINE HANGER
REMOVE ENGINE FROM ENGINE STAND
Using a chain block and engine sling device, secure the engine assembly.
Note:Adjust the angle of the sling device carefully to prevent the engine assembly or engine hangers from deforming or becoming damaged.
Servicing an engine assembly while it is hanging is dangerous. This can be done only when installing/removing the engine assembly to/from an engine stand.
Remove the engine assembly from the engine stand.
INSTALL ENGINE WIRE
Connect all the clamps and connectors, and install the engine wire to the engine assembly.
-
*1
Nut
*2
Wire Harness Bracket
Install the 3 bolts and nut to the cylinder head sub-assembly.
Bolt A and Nut
8.0 N*m
82 kgf*cm
71 in.*lbf
Bolt B
8.5 N*m
87 kgf*cm
75 in.*lbf
Install the wire harness bracket to the cylinder head cover sub-assembly with the bolt.
8.0 N*m
82 kgf*cm
71 in.*lbf
Install the 2 nuts to the cylinder head cover sub-assembly.
8.0 N*m
82 kgf*cm
71 in.*lbf
INSPECT ONE-WAY CLUTCH ASSEMBLY (w/ Stop and Start System)
INSTALL INNER OIL SEAL (w/ Stop and Start System)
INSTALL RING GEAR SUB-ASSEMBLY (w/ Stop and Start System)
INSPECT RING GEAR SUB-ASSEMBLY (w/ Stop and Start System)
INSTALL ONE-WAY CLUTCH ASSEMBLY (w/ Stop and Start System)
INSTALL FLYWHEEL SUB-ASSEMBLY
INSTALL CLUTCH DISC ASSEMBLY
INSTALL CLUTCH COVER ASSEMBLY
INSPECT AND ADJUST CLUTCH COVER ASSEMBLY
INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY
REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY
INSPECT CLUTCH PIPE LINE
INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY
INSTALL BLEEDER CLUTCH RELEASE TUBE
INSTALL MANUAL TRANSAXLE ASSEMBLY
CONNECT WIRE HARNESS (w/ Stop And Start System)
CONNECT WIRE HARNESS (w/o Stop And Start System)
INSTALL STARTER ASSEMBLY (w/ Stop and Start System)
INSTALL STARTER ASSEMBLY (w/o Stop and Start System)
INSTALL GENERATOR ASSEMBLY (for 80 A Type)
INSTALL GENERATOR ASSEMBLY (for 100 A Type)
INSTALL COMPRESSOR ASSEMBLY WITH PULLEY (w/ Air Conditioning System)
INSTALL FLYWHEEL HOUSING SIDE COVER (w/ Stop and Start System)
INSTALL FLYWHEEL HOUSING SIDE COVER (w/o Stop and Start System)
INSTALL ENGINE MOUNTING INSULATOR LH
Tip:Perform this procedure only when replacement of the engine mounting insulator LH is necessary.
Install the engine mounting insulator LH with the 4 bolts.
95 N*m
969 kgf*cm
70 ft.*lbf
INSTALL ENGINE MOUNTING INSULATOR RH
Tip:Perform this procedure only when replacement of the engine mounting insulator RH is necessary.
Install the engine mounting insulator RH with the 3 bolts.
95 N*m
969 kgf*cm
70 ft.*lbf
Connect the cooler pipe clamp to the engine mounting insulator RH.
Install the cooler pipe clamp bracket to the engine mounting insulator RH with the bolt.
9.8 N*m
100 kgf*cm
87 in.*lbf
Connect the radiator reservoir tank with the 2 bolts.
5.0 N*m
51 kgf*cm
44 in.*lbf
TEMPORARILY TIGHTEN REAR ENGINE MOUNTING INSULATOR
Temporarily install the rear engine mounting insulator to the rear engine mounting bracket with the through bolt.
TEMPORARILY TIGHTEN FRONT ENGINE MOUNTING INSULATOR
Temporarily install the front engine mounting insulator to the front engine mounting bracket with the through bolt and nut.
INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
Set the engine assembly with transaxle on the engine lifter.
Note:Place height adjustment attachments and plate lift attachments under the engine assembly with transaxle.
Remove the 2 bolts, No. 1 engine hanger and No. 2 engine hanger.
Operate the engine lifter and lift the engine assembly with transaxle to the position where the engine mounting insulators RH and LH can be installed.
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 assembly with transaxle is clear of all wiring and hoses.
While raising the engine assembly with transaxle into the vehicle, do not allow it to contact the vehicle.
Install the engine mounting insulator LH with the through bolt and nut.
56 N*m
571 kgf*cm
41 ft.*lbf
Tip:When tightening the through bolt, keep the nut from rotating.
Install the engine mounting insulator RH with the bolt and 2 nuts.
52 N*m
530 kgf*cm
38 ft.*lbf
Install the front cross member sub-assembly with the 4 bolts.
99 N*m
1010 kgf*cm
73 ft.*lbf
Connect the front engine mounting insulator to the front cross member sub-assembly with the 2 bolts.
95 N*m
969 kgf*cm
70 ft.*lbf
CONNECT NO. 1 CLUTCH HOSE
Install a new clip to connect the No. 1 clutch hose to the flexible hose bracket.
Using a 10 mm union nut wrench, connect the No. 1 clutch hose to the bleeder clutch release tube.
15.2 N*m
155 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.
INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
INSTALL FRONT SUSPENSION MEMBER REAR BRACE LH
INSTALL FRONT SUSPENSION MEMBER REAR BRACE RH
Tip:Perform the same procedure as for the LH side.
INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH
INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH
INSTALL FRONT ENGINE MOUNTING BRACKET LOWER REINFORCEMENT (w/ Reinforcement)
FULLY TIGHTEN REAR ENGINE MOUNTING INSULATOR
Tighten the rear engine mounting insulator to the engine mounting bracket with the through bolt.
95 N*m
969 kgf*cm
70 ft.*lbf
FULLY TIGHTEN FRONT ENGINE MOUNTING INSULATOR
Tighten the front engine mounting insulator with the bolt and nut.
85 N*m
867 kgf*cm
63 ft.*lbf
Tip:When tightening the through bolt, keep the nut from rotating.
INSTALL FRONT DRIVE SHAFT ASSEMBLY
INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)
CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY
CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY
INSTALL COLUMN HOLE COVER SILENCER SHEET
CONNECT WIRE HARNESS
Connect the No. 3 engine wire to the manual transaxle assembly with the bolt.
12.5 N*m
127 kgf*cm
9 ft.*lbf
Connect the 2 wire harness clamps to the battery carrier.
Connect the 3 wire harness connectors and wire harness to the engine room junction block and engage the 2 claws.
Install the 2 nuts to the engine room relay block and junction block assembly.
8.5 N*m
87 kgf*cm
75 in.*lbf
Install the No. 1 relay block cover to the engine room relay block and junction block assembly.
Connect the wire harness clamp.
Connect the ECM connector and lower the lever.
INSTALL V-RIBBED BELT
CONNECT FUEL TUBE SUB-ASSEMBLY
CONNECT SUCTION HOSE SUB-ASSEMBLY (w/ Air Conditioning System)
CONNECT DISCHARGE HOSE SUB-ASSEMBLY (w/ Air Conditioning System)
CONNECT HEATER WATER INLET HOSE A
Connect the heater water inlet hose A to the cylinder head sub-assembly and slide the clip to secure it.
Connect the hose clamp.
CONNECT HEATER WATER OUTLET HOSE A
Connect the heater water outlet hose A to the No. 1 water by-pass pipe and slide the clip to secure it.
Connect the 2 hose clamps.
CONNECT UNION TO CONNECTOR TUBE HOSE (for LHD)
Connect the union to connector tube hose to the intake manifold and slide the clip to secure it.
CONNECT CHECK VALVE TO BRAKE BOOSTER HOSE (for RHD)
Connect the check valve to brake booster hose to the intake manifold and slide the clip to secure it.
INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY
Install the transmission control cable assembly to the rear engine mounting bracket with the bolt.
5.0 N*m
51 kgf*cm
44 in.*lbf
-
Install the 2 transmission control cable assemblies to the control cable bracket with 2 new clips (A).
Install the 2 transmission control cable assemblies to the manual transaxle assembly with the 2 clips (B).
Connect the clip and clamp, and install the wire harness with the nut.
8.0 N*m
82 kgf*cm
71 in.*lbf
CONNECT NO. 2 RADIATOR HOSE
Connect the No. 2 radiator hose to the radiator assembly and slide the clip to secure it.
CONNECT NO. 1 RADIATOR HOSE
Connect the No. 1 radiator hose to the cylinder head sub-assembly and slide the clip to secure it.
Install the radiator pipe to the battery carrier with the 2 bolts.
18.5 N*m
189 kgf*cm
14 ft.*lbf
INSTALL BATTERY
Install the battery tray to the battery carrier.
Install the battery to the battery tray.
Install the battery clamp sub-assembly with the bolt and nut.
Bolt
16.5 N*m
168 kgf*cm
12 ft.*lbf
Nut
3.5 N*m
36 kgf*cm
31 in.*lbf
Connect the positive (+) cable to the positive (+) battery terminal with the nut.
5.4 N*m
55 kgf*cm
48 in.*lbf
INSTALL AIR CLEANER CASE SUB-ASSEMBLY
Install the air cleaner case sub-assembly with the 3 bolts.
7.0 N*m
71 kgf*cm
62 in.*lbf
Connect the engine wire harness clamp to the air cleaner case sub-assembly.
Install the air cleaner filter element sub-assembly to the air cleaner case sub-assembly.
INSTALL AIR CLEANER CAP SUB-ASSEMBLY
INSTALL PURGE VALVE (PURGE VSV)
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Connect the cable to the negative (-) battery terminal.
5.4 N*m
55 kgf*cm
48 in.*lbf
Note:When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
FILL BRAKE FLUID RESERVOIR
BLEED CLUTCH LINE
INSPECT BRAKE FLUID LEVEL IN RESERVOIR
INSPECT FOR FLUID LEAK
Tip:Check for leaks in the clutch system.
ADJUST TRANSMISSION CONTROL CABLE ASSEMBLY
ADD MANUAL TRANSAXLE OIL
ADD ENGINE COOLANT
ADD ENGINE OIL
INSPECT MANUAL TRANSAXLE OIL
CHECK ENGINE OIL LEVEL
INSPECT FOR FUEL LEAK
INSPECT FOR COOLANT LEAK
INSPECT FOR OIL LEAK
INSPECT FOR EXHAUST GAS LEAK
CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT (w/ Air Conditioning System)
WARM UP ENGINE (w/ Air Conditioning System)
INSPECT FOR REFRIGERANT LEAK (w/ Air Conditioning System)
INSTALL REAR ENGINE UNDER COVER LH
Install the rear engine under cover LH with the 5 clips.
INSTALL REAR ENGINE UNDER COVER RH
Install the rear engine under cover RH with the 5 clips.
INSTALL CENTER NO. 4 ENGINE UNDER COVER
Install the center No. 4 engine under cover with the 5 clips.
INSTALL NO. 1 ENGINE UNDER COVER (for Half Cover Type)
Install the No. 1 engine under cover with the 2 bolts and 7 clips.
INSTALL NO. 1 ENGINE UNDER COVER (for Metal Type)
Install the No. 1 engine under cover with the 5 bolts and 2 clips.
INSTALL FRONT LOWER BUMPER ABSORBER
Install the front lower bumper absorber with the 8 bolts and 4 screws.
INSTALL FRONT WHEELS
103 N*m
1050 kgf*cm
76 ft.*lbf
INSPECT IGNITION TIMING
INSPECT ENGINE IDLE SPEED
INSPECT CO/HC
ADJUST FRONT WHEEL ALIGNMENT
INSTALL NO. 1 ENGINE COVER
Engage the 2 front clips, then the rear clip to install the No. 1 engine cover.
Note:Be sure to engage the clips securely.
Do not apply excessive force or tap the No. 1 engine cover to engage the clips. This may cause the No. 1 engine cover to break.
CHECK FOR SPEED SENSOR SIGNAL
w/o VSC:Click here
w/ VSC:Click here