ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

Note

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.

PROCEDURE


  1. INSTALL ENGINE MOUNTING INSULATOR LH

    A01VI73E02

    Tech Tips

    Only perform this procedure when replacement of the engine mounting insulator LH is necessary.


    1. Temporarily install the engine mounting insulator LH with the 3 bolts.

    2. Fully tighten the 3 bolts, in the order shown in the illustration.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

  2. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    A01VL9AE02

    Tech Tips

    Only perform this procedure when replacement of the engine mounting insulator RH is necessary.


    1. Temporarily install the engine mounting insulator RH with the 3 bolts.

    2. Fully tighten the 3 bolts, in the order shown in the illustration.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

  3. INSTALL FLYWHEEL SUB-ASSEMBLY

    Click here

  4. INSTALL CLUTCH DISC ASSEMBLY

    Click here

  5. INSTALL CLUTCH COVER ASSEMBLY

    Click here

  6. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY

    Click here

  7. INSTALL ENGINE ASSEMBLY

    A01VGD7E01

    1. Align the input shaft with the clutch disc and install the engine to the manual transaxle.

    2. Install the 9 bolts.

      Torque:
      Bolt A
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
      Bolt B
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

      Note

      Insert knock pins into the knock pin holes securely so that the end face of the transaxle fits close against the engine before tightening the bolts.

  8. INSTALL STARTER ASSEMBLY

    Click here

  9. INSTALL FLYWHEEL HOUSING SIDE COVER

    Click here

  10. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine.

  11. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    1. Place wooden blocks or plate lift attachments on an engine lifter, and then set the engine assembly with transaxle.

      Note


      • Place the wooden blocks or plate lift attachments so that the engine assembly with transaxle is level.

      • As the engine assembly with transaxle is very heavy, be sure to support it securely.

    2. Operate the engine lifter and lift the engine assembly with transaxle and the front suspension crossmember to the position where the engine mounting insulators RH and LH can be installed.

    3. A01VKU8E02
      Text in Illustration
      *1 Through Bolt

      Temporarily install the engine mounting insulator LH with the bolt, through bolt and nut.

    4. Fully tighten the bolt A.

      Torque:
      Bolt A
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

    5. Fully tighten the through bolt and nut.

      Torque:
      Through Bolt
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

    6. Install the engine mounting insulator RH with the bolt and 2 nuts.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

    7. By inserting SST into the datum holes in the front suspension crossmember RH and LH alternately, tighten bolts A, B and C on both sides to the specified torque, in several steps.

      A01VHZEE04
      Text in Illustration
      *a Datum Hole *b OK
      *c NG - -
      A01VL3H Front of the Vehicle - -
      SST
      09670-00011
      Torque:
      Bolt A
      87 N*m  { 887 kgf*cm, 64 ft.*lbf }
      Bolt B
      151 N*m  { 1540 kgf*cm, 111 ft.*lbf }
      Bolt C
      98 N*m  { 999 kgf*cm, 72 ft.*lbf }

      Note


      • Insert SST into the datum hole vertically.

      • If impossible to insert SST vertically, loosen all bolts and then insert SST again.

    8. Install the wire harness clamp bracket with the bolt.

      T = 29 N*m{ kgf*cm 21 ft.*lbf }

  12. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  13. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY

    Click here

  14. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  15. INSTALL FRONT DRIVE SHAFT ASSEMBLY

    Click here

  16. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    Click here

  17. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY

    Click here

  18. INSTALL RELEASE CYLINDER HEAT INSULATOR

    Click here

  19. CONNECT ENGINE WIRE


    1. Engage the wire harness clamp.

    2. Install the bolt and connect the ground wire from the transaxle.

      Torque:
      26 N*m  { 260 kgf*cm, 19 ft.*lbf }

    3. Engage the 2 claws and connect the wire harness to the junction block.

    4. Connect the connector to the engine junction block.

    5. Disengage the wire harness clamp.

    6. Remove the engine junction block cover.

    7. Connect the connector to the ECM, and slide the lever to engage the lock.

      Note


      • Make sure that the levers are securely locked.

    8. Connect the current sensor connector to the negative (-) battery terminal.

    9. Connect the 2 connectors to the positive (+) battery terminal.

  20. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  21. CONNECT NO. 2 HEATED OXYGEN SENSOR WIRE HARNESS


    1. Engage the 3 clamps and connect the No. 2 heated oxygen sensor wire to the fan shroud.

    2. Connect the No. 2 heated oxygen sensor connector.

  22. INSTALL TAIL EXHAUST PIPE ASSEMBLY

    A01VHU2

    1. Using a vernier caliper, measure the free length of the compression spring.

      Minimum Length
      38.5 mm (1.516 in.)

      Tech Tips

      If the length is not as specified, replace the compression spring.

    2. A01VIW9E07
      Text in Illustration
      *1 Exhaust Pipe Gasket
      *2 Wooden Block
      *3 Plastic Hammer
      *4 Front Exhaust Pipe Assembly

      Using a plastic hammer and a wooden block, tap in a new exhaust pipe gasket until its surface is flush with the front exhaust pipe.

      Note


      • Install the gasket in the correct direction.

      • Do not reuse the gasket.

      • Do not damage the gasket by dropping it, etc.

      • Do not damage the outer surface of the gasket.

      • Do not push in the gasket with the exhaust pipe when connecting it.

    3. A01VJB1E01
      Text in Illustration
      *1 Front Exhaust Pipe Assembly
      *2 Tail Exhaust Pipe Assembly
      *3 Exhaust Pipe Gasket
      *a Space between flanges: 6.5 mm (0.256 in.)

      Install the front exhaust pipe to the exhaust manifold converter with the 2 compression springs and 2 bolts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

      Note

      After the installation, check that the gaps between the flanges of the front exhaust pipe and tail exhaust pipe are consistent front-to-rear and left-to-right.

  23. INSTALL FRONT FLOOR CENTER BRACE

    Click here

  24. CONNECT NO. 2 RADIATOR HOSE


    1. Connect the No. 2 radiator hose to the water inlet.

  25. CONNECT NO. 1 RADIATOR HOSE


    1. Connect the No. 1 radiator hose to the cylinder head.

  26. CONNECT BOOSTER VACUUM TUBE


    1. Connect the booster vacuum tube connector to the intake manifold.

    2. Engage the booster vacuum tube to the hose clamp.

  27. CONNECT INLET HEATER WATER HOSE A


    1. Connect the inlet heater water hose to the air conditioning unit.

  28. CONNECT OUTLET HEATER WATER HOSE A


    1. Connect the outlet heater water hose to the air conditioning unit.

  29. CONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. Connect the No. 1 fuel vapor feed hose to the duty vacuum switching valve.

    2. Engage the No. 1 fuel vapor feed hose to the hose clamp.

  30. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. Connect the fuel tube Click here.

  31. INSTALL EFI FUEL PIPE CLAMP


    1. Install the fuel pipe clamp.

  32. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY


    1. A01VLN3E02

      Temporarily install the compressor with the 4 bolts.

    2. Fully tighten the 4 bolts, in the order shown in the illustration.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

    3. Connect the compressor connector.

  33. INSTALL GENERATOR ASSEMBLY

    Click here

  34. INSTALL FAN AND GENERATOR V BELT

    Click here

  35. INSTALL BATTERY CARRIER (for LHD)


    1. Install the battery carrier with the 4 bolts.

      Torque:
      17 N*m  { 175 kgf*cm, 13 ft.*lbf }

    2. Engage the 4 clamps and connect the wire harness onto the battery carrier.

  36. INSTALL BATTERY CARRIER (for RHD)


    1. Install the battery carrier with the 4 bolts.

      Torque:
      17 N*m  { 175 kgf*cm, 13 ft.*lbf }

    2. Engage the 5 clamps and connect the wire harness onto the battery carrier.

  37. INSTALL BATTERY TRAY


    1. Install the battery tray.

  38. INSTALL BATTERY


    1. Install the battery onto the battery tray.

    2. Install the battery clamp with the 2 nuts.

      Torque:
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

    3. Connect the cable to the positive (+) battery terminal.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  39. INSTALL FRONT WHEEL

    Torque:
    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }

  40. INSPECT FAN AND GENERATOR V BELT

    Click here

  41. ADD ENGINE OIL

  42. ADD ENGINE COOLANT

    Click here

  43. ADD MANUAL TRANSAXLE OIL

    Click here

  44. INSPECT ENGINE OIL LEVEL

    Click here

  45. INSPECT FOR ENGINE OIL LEAK

  46. INSPECT FOR COOLANT LEAK

  47. INSPECT FOR EXHAUST GAS LEAK

  48. INSPECT FOR FUEL LEAK

  49. INSTALL ENGINE UNDER COVER RH

    Torque:
    5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  50. INSTALL ENGINE UNDER COVER LH

    Torque:
    5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  51. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  52. CHECK SPEED SENSOR SIGNAL (w/o VSC)

    Click here

  53. CHECK SPEED SENSOR SIGNAL (for TMC Made with VSC)

    Click here

  54. CHECK SPEED SENSOR SIGNAL (for TMMF Made with VSC)

    Click here