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 HANGER

    Click here

  2. INSTALL ENGINE MOUNTING INSULATOR LH

    B0046MAE03
    Text in Illustration
    *a Temporarily Tighten

    Tech Tips

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


    1. Engage the hook to temporarily install the engine mounting insulator LH to the vehicle.

    2. Install the 3 bolts in the sequence shown in the illustration.

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

  3. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    B0045BDE02
    Text in Illustration
    *a Temporarily Tighten

    Tech Tips

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


    1. Engage the hook to temporarily install the engine mounting insulator sub-assembly RH to the vehicle.

    2. Install the 3 bolts in the sequence shown in the illustration.

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

  4. REMOVE ENGINE STAND


    1. Using a chain block and a sling device, secure the engine assembly.

      Note

      Make sure that the sling angle is correct to prevent the engine assembly and engine hangers from being damaged or deformed.

    2. Remove the engine stand from the engine assembly.

  5. INSTALL FLYWHEEL SUB-ASSEMBLY

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  6. INSTALL CLUTCH DISC ASSEMBLY

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  7. INSTALL CLUTCH COVER ASSEMBLY

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  8. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY

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  9. INSTALL MANUAL TRANSAXLE ASSEMBLY

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  10. INSTALL STARTER ASSEMBLY (w/ Stop And Start System)

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  11. INSTALL STARTER ASSEMBLY (for Cold Area Specification Vehicles)

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  12. INSTALL STARTER ASSEMBLY (except Cold Area Specification Vehicles)

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  13. INSTALL FLYWHEEL HOUSING SIDE COVER (w/ Stop And Start System)

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  14. INSTALL FLYWHEEL HOUSING SIDE COVER (for Cold Area Specification Vehicles)

    Click here

  15. INSTALL FLYWHEEL HOUSING SIDE COVER (except Cold Area Specification Vehicles)

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  16. INSTALL ENGINE WIRE


    1. Connect all the wire harnesses and connectors.

    2. Connect the engine wire to the cylinder head sub-assembly with the bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

  17. REMOVE ENGINE HANGER

    Click here

  18. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the wire harness clamp bracket to the cylinder head sub-assembly with the bolt.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

    2. Engage the clamp and connect the engine wire to the wire harness clamp bracket.

  19. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


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

      Note


      • Place the height adjustment or plate lift attachments so that the engine assembly with manual transaxle assembly 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 to the position where the engine mounting insulator sub-assembly RH and engine mounting insulator LH can be installed.

    3. Install the engine mounting insulator LH with the bolt, through bolt and nut.

      Torque:
      Bolt
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
      Torque:
      Through bolt
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

      Note


      • Make sure that the engine assembly with transaxle is clear of all wiring and hoses.

      • Tighten the bolt first, and then tighten the through bolt.

      Tech Tips

      Tighten by holding the nut and turning the through bolt.

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

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

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

      B0046G1E04
      Text in Illustration
      *a Datum Hole *b OK
      *c NG - -
      B0046MU 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.

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

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  21. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY

    Click here

  22. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  23. INSTALL FRONT DRIVE SHAFT ASSEMBLY

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  24. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

    Click here

  25. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

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  26. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY

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  27. INSTALL RELEASE CYLINDER HEAT INSULATOR

    Click here

  28. CONNECT ENGINE WIRE


    1. w/ Stop and Start System:


      1. Install the wire harness clamp bracket to the clutch flexible hose bracket with the bolt.

        Torque:
        13 N*m  { 130 kgf*cm, 9 ft.*lbf }

      2. Engage the 2 clamp to connect the engine wire to the wire harness clamp bracket.

      3. Connect the neutral position switch connector.

    2. Engage the 2 clamps to connect engine wire from the transaxle.

    3. Connect the engine wire to the transaxle with the bolt.

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

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

    5. Engage the 2 claws to connect the engine wire to the engine room relay block.

    6. Connect the connector to the engine room relay block.

    7. Engage the clamp to connect the engine wire to the vehicle.

    8. Install the engine room relay block cover.

    9. for LHD:


      1. B0046BQE02
        Text in Illustration
        *A for LHD
        *B for RHD

        Engage the clamp to connect the engine wire from the wire harness clamp bracket.

    10. Connect the ECM connector and lock the lever.

      Note


      • Make sure that the levers are securely locked.

  29. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. B0045YAE06
      Text in Illustration
      *1 Front Exhaust Pipe Assembly
      *2 No. 2 Exhaust Pipe Gasket
      *a Wooden Block
      *b Plastic Hammer

      Using a plastic hammer and a wooden block, tap in a new No. 2 exhaust pipe gasket until its surface is flush with the front exhaust pipe assembly.

      Note


      • Install the No. 2 exhaust pipe gasket in the correct direction.

      • Do not reuse the No. 2 exhaust pipe gasket.

      • Do not damage the No. 2 exhaust pipe gasket by dropping it, etc.

      • Do not damage the outer surface of the No. 2 exhaust pipe gasket.

      • Do not push in the No. 2 exhaust pipe gasket with the tail exhaust pipe assembly when connecting it.

    2. B0045YAE07
      Text in Illustration
      *1 Exhaust Manifold
      *2 Exhaust Pipe Gasket
      *a Wooden Block
      *b Plastic Hammer

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

      Note


      • Install the exhaust pipe gasket in the correct direction.

      • Do not reuse the exhaust pipe gasket.

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

      • Do not damage the outer surface of the exhaust pipe gasket.

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

    3. B00487A

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

      Free Length of Compression Spring
      Compression Spring Standard Length Minimum Length
      Front Side 43 mm (1.69 in.) 41.5 mm (1.63 in.)
      Rear Side 40 mm (1.57 in.) 38.5 mm (1.52 in.)

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

    4. Connect the 3 exhaust pipe supports to install the front exhaust pipe assembly to the vehicle.

    5. B0045FFE06
      Text in Illustration
      *1 Exhaust Manifold
      *2 Front Exhaust Pipe Assembly
      *3 Exhaust Pipe Gasket
      *a Space between flanges: 8.5 mm (0.335 in.)

      Connect the front exhaust pipe sub-assembly to the exhaust manifold 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 exhaust manifold and front exhaust pipe assembly are consistent front-to-rear and left-to-right.

    6. B00456BE02
      Text in Illustration
      *1 Front Exhaust Pipe Assembly
      *2 Tail Exhaust Pipe Assembly
      *3 No. 2 Exhaust Pipe Gasket
      *a Space between flanges: 6.5 mm (0.256 in.)

      Connect the front exhaust pipe assembly to the tail exhaust pipe assembly 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 tail exhaust pipe assembly and front exhaust pipe assembly are consistent front-to-rear and left-to-right.

    7. Engage the 3 clamps to connect the No. 2 heated oxygen sensor connector wire to the fan shroud.

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

  30. INSTALL FRONT FLOOR CENTER BRACE

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  31. CONNECT NO. 2 RADIATOR HOSE


    1. Connect the No. 2 radiator hose to the water inlet and slide the hose clip to secure it.

  32. CONNECT NO. 1 RADIATOR HOSE


    1. Connect the No. 1 radiator hose to the cylinder head sub-assembly and slide the hose clip to secure it.

  33. CONNECT VACUUM HOSE ASSEMBLY

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  34. CONNECT INLET HEATER WATER HOSE A


    1. Connect the inlet heater water hose A to the heater unit and slide the hose clip to secure it.

  35. CONNECT OUTLET HEATER WATER HOSE A


    1. Connect the outlet heater water hose A to the heater unit and slide the hose clip to secure it.

  36. CONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. Connect the No. 1 fuel vapor feed hose to the duty vacuum switching valve and slide the hose clip to secure it.

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

  37. CONNECT FUEL TUBE SUB-ASSEMBLY

    Note

    Check if there is any damage or foreign matter on the connecting parts of the fuel lines.


    1. B0047O6E02
      Text in Illustration
      *1 Retainer
      *2 Nylon Tube
      *3 Pipe
      *4 O-ring
      *5 Fuel Tube Connector
      B0046MU Push

      Connect the fuel tube sub-assembly to the fuel tube.


      1. Align the fuel tube connector with the fuel pipe, and push them together until the fuel tube connector makes a "click" sound. If it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean engine oil to the tip of the fuel pipe and reinsert it.

      2. After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

  38. INSTALL EFI FUEL PIPE CLAMP


    1. Install the EFI fuel pipe clamp to the fuel tube sub-assembly and fuel tube.

  39. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY (w/ Air Conditioning System)


    1. B0045DDE02

      Temporarily install the compressor assembly with pulley to the cylinder block sub-assembly and oil pan sub-assembly.

    2. Fully tighten the 4 bolts in the sequence shown in the illustration.

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

    3. Connect the compressor assembly with pulley connector.

  40. INSTALL GENERATOR ASSEMBLY (for DENSO Made)

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  41. INSTALL GENERATOR ASSEMBLY (for VALEO Made)

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  42. INSTALL FAN AND GENERATOR V BELT

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  43. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

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  44. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

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  45. INSTALL INLET NO. 1 AIR CLEANER

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  46. INSTALL BATTERY CARRIER


    1. Install the battery carrier to the vehicle with the 4 bolts.

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

    2. Engage the 5 clamps to connect the engine wire to the battery carrier.

  47. INSTALL BATTERY TRAY


    1. Install the battery tray to the battery carrier.

  48. INSTALL BATTERY


    1. B0047SL

      Install the battery to the battery tray.

    2. Install the battery clamp sub-assembly to the battery carrier with the 2 nuts.

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

      Tech Tips

      Engage the hook of the battery clamp bolt to the hole of the battery carrier.

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

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

    4. Close the positive (+) battery terminal cover.

  49. INSTALL FRONT WHEEL

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

  50. ADD ENGINE OIL

  51. ADD ENGINE COOLANT

    Click here

  52. ADD MANUAL TRANSAXLE OIL

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  53. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    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 Click here.

  54. INSPECT ENGINE OIL LEVEL

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  55. INSPECT FOR ENGINE OIL LEAK

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  56. INSPECT FOR COOLANT LEAK

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  57. INSPECT FOR EXHAUST GAS LEAK

  58. INSPECT FOR FUEL LEAK

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  59. INSTALL OUTER COWL TOP PANEL (for LHD)

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  60. INSTALL OUTER COWL TOP PANEL (for RHD)

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  61. INSTALL INNER COWL TOP TO COWL BRACE (for LHD)

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  62. INSTALL INNER COWL TOP TO COWL BRACE (for RHD)

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  63. INSTALL FRONT NO. 1 VENTILATOR SEAL (for LHD)

    Click here

  64. INSTALL FRONT NO. 1 VENTILATOR SEAL (for RHD)

    Click here

  65. INSTALL FRONT AIR SHUTTER SEAL RH (for LHD)

    Click here

  66. INSTALL FRONT AIR SHUTTER SEAL RH (for RHD)

    Click here

  67. INSTALL WINDSHIELD WIPER MOTOR AND LINK

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  68. INSTALL ENGINE UNDER COVER RH


    1. Install the 2 bolts, screw and engine under cover RH to the vehicle.

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

  69. INSTALL ENGINE UNDER COVER LH


    1. Install the 3 bolts, 3 screws and engine under cover LH to the vehicle.

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

  70. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

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  71. INSPECT SPEED SENSOR SIGNAL

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