ENGINE ASSEMBLY

INSTALL ENGINE MOUNTING INSULATOR LH

Tech Tips

Perform this procedure only when replacement of the engine mounting insulator LH is necessary.

*a Temporarily Tighten

Engage the hook and temporarily install the engine mounting insulator LH to the vehicle.
Install the 5 bolts in the order shown in the illustration.

Torque:

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

INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

Tech Tips

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

*a Temporarily Tighten

Engage the hook and temporarily install the engine mounting insulator sub-assembly RH to the vehicle.
Install the 3 bolts in the order shown in the illustration.

Torque:

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

INSTALL ENGINE HANGER

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REMOVE ENGINE STAND

Using an engine sling device and chain block, secure the engine assembly.
Note
- Pay attention to the angle of the engine sling device as the engine assembly or engine hanger may be damaged or deformed if the angle is incorrect.
- Do not perform any procedure while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.
Remove the engine assembly from the engine stand.

INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for CVT)

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INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)

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INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY (for CVT)

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INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)

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INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

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CONNECT WATER INLET HOSE (for CVT)

Connect the water inlet hose to the No. 2 water by-pass pipe and slide the hose clip to secure it.

INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT (for CVT)

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INSTALL FLYWHEEL HOUSING SIDE COVER

Install the flywheel housing side cover to the cylinder block sub-assembly.

INSTALL STARTER ASSEMBLY

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INSTALL ENGINE WIRE

Connect all of the connectors and wire harness clamps, and install the engine wire to the engine assembly.
Connect the engine wire to the cylinder head cover sub-assembly with the 2 nuts.

Torque:

8.4 N*m { 86 kgf*cm, 74 in.*lbf }
Connect the engine wire to the cylinder head sub-assembly with the 2 bolts.

Torque:

Bolt A

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

Bolt B

12.8 N*m { 131 kgf*cm, 9 ft.*lbf }
Connect the engine wire to the transaxle assembly with the bolt.

Torque:

12.8 N*m { 131 kgf*cm, 9 ft.*lbf }

CONNECT VENTILATION HOSE ASSEMBLY

Connect the ventilation hose assembly to the heater water pipe and slide the hose clip to secure it.

CONNECT INLET HEATER WATER HOSE A (for CVT)

Connect the inlet heater water hose A to the cylinder head sub-assembly and exhaust cooler assembly and slide the 2 hose clips to secure them.
Engage the 2 clamps.

CONNECT INLET HEATER WATER HOSE A (for Manual Transaxle)

Connect the inlet heater water hose A to the cylinder head sub-assembly and exhaust cooler assembly and slide the 2 hose clips to secure them.
Engage the clamp.

INSTALL ENGINE WITH TRANSAXLE ASSEMBLY

Tech Tips

Perform "Inspection After Repair" after replacing the engine assembly.

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Set the engine with transaxle assembly and front suspension crossmember sub-assembly on an engine lifter.
Note
- Keep the engine with transaxle assembly and front crossmember sub-assembly horizontal.
- As the engine with transaxle assembly is very heavy, be sure to support it securely.
Remove the 2 bolts, No. 1 engine hanger and No. 2 engine hanger from the cylinder head sub-assembly.
Operate the engine lifter and connect the engine mounting insulator sub-assembly RH to the timing chain cover assembly with the bolt and 2 nuts.

Torque:

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

Note

Make sure that the engine is clear of all wiring and hoses.
Operate the engine lifter and connect the engine mounting insulator LH to the engine mounting bracket LH with the through bolt and nut.

Torque:

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

Note

Make sure that the engine is clear of all wiring and hoses.

Tech Tips

Tighten by holding the nut and turning the through bolt.

Temporarily install the front suspension crossmember sub-assembly to the vehicle with the 6 bolts.

*a	Correct	*b	Incorrect
	Front Side of Vehicle	-	-

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.

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.

INSTALL WIRE HARNESS CLAMP BRACKET

Install the wire harness clamp bracket to the transaxle assembly with the bolt.

Torque:

63 N*m { 642 kgf*cm, 46 ft.*lbf }
Engage the 2 clamps and connect the engine wire to the wire harness clamp bracket.

INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

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INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY

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INSTALL COLUMN HOLE COVER SILENCER SHEET

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CONNECT ENGINE WIRE (for LHD)

Engage the clamp to connect the engine wire to the battery current sensor holder.
Connect the battery state sensor assembly connector.
Connect the 2 connectors of the positive (+) battery terminal.
Engage the 2 claws to connect the engine wire to the engine room relay block.
Connect the 2 connectors to the engine room relay block.
Engage the clamp to connect the engine wire to the vehicle.
Connect the engine wire to the vehicle with the bolt.

Torque:

8.4 N*m { 86 kgf*cm, 74 in.*lbf }
Install the relay block cover to the engine room relay block.
Connect the ECM connector and lock with the lever.
Note
- When connecting connectors, make sure that foreign substances such as mud or water droplets do not adhere to them.
- Securely lock with the lever.
Engage the clamp.
Engage the clamp to connect the engine wire to the air cleaner bracket.

CONNECT ENGINE WIRE (for RHD)

Engage the clamp to connect the engine wire to the battery current sensor holder.
Connect the battery state sensor assembly connector.
Connect the 2 connectors of the positive (+) battery terminal.
Engage the 2 claws to connect the engine wire to the engine room relay block.
Connect the 2 connectors to the engine room relay block.
Engage the clamp to connect the engine wire to the vehicle.
Connect the engine wire to the vehicle with the bolt.

Torque:

8.4 N*m { 86 kgf*cm, 74 in.*lbf }
Install the relay block cover to the engine room relay block.
Connect the ECM connector and lock with the lever.
Note
- When connecting connectors, make sure that foreign substances such as mud or water droplets do not adhere to them.
- Securely lock with the lever.
Engage the clamp to connect the engine wire to the air cleaner bracket.

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

Using an E8 "TORX" socket wrench, install the compressor with pulley assembly to the cylinder block sub-assembly and oil pan sub-assembly with the stud bolt.

Torque:

9.8 N*m { 100 kgf*cm, 87 in.*lbf }
Bolt

Nut

Temporarily install the compressor with pulley assembly to the cylinder block sub-assembly and oil pan sub-assembly with the 3 bolts and nut.
Fully tighten the 3 bolts and nut in the order shown in the illustration.

Torque:

24.5 N*m { 250 kgf*cm, 18 ft.*lbf }

INSTALL CLUTCH HOSE (for Manual Transaxle)

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CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for CVT)

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CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)

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CONNECT FUEL TUBE SUB-ASSEMBLY

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INSTALL NO. 2 EFI FUEL PIPE CLAMP

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CONNECT INLET HEATER WATER HOSE A

Connect the inlet heater water hose A to the heater radiator assembly and slide the hose clip to secure it.

Note

Do not apply excessive force to the inlet heater water hose A.

CONNECT OUTLET HEATER WATER HOSE A

Connect the outlet heater water hose A to the heater radiator assembly and slide the hose clip to secure it.

Note

Do not apply excessive force to the outlet heater water hose A.

CONNECT NO. 2 RADIATOR HOSE

Connect the No. 2 radiator hose to the water inlet with thermostat sub-assembly and slide the hose clip to secure it.

CONNECT NO. 1 RADIATOR HOSE

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

INSTALL GENERATOR ASSEMBLY

for DENSO Made:

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for VALEO Made:

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INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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INSTALL OIL LEVEL DIPSTICK GUIDE O-RING

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INSTALL OIL LEVEL DIPSTICK GUIDE

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INSTALL OIL LEVEL DIPSTICK SUB-ASSEMBLY

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INSTALL FAN AND GENERATOR V BELT

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CONNECT UNION TO CONNECTOR TUBE HOSE

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CONNECT FUEL VAPOR FEED HOSE ASSEMBLY

Engage the clamp to connect the hose clamp to the No. 3 water by-pass hose.
Connect the fuel vapor feed hose assembly to the purge valve (purge VSV) and slide the hose clip to secure it.

INSTALL BATTERY CARRIER

Install the battery carrier to the vehicle with the 5 bolts.

Torque:

17.2 N*m { 175 kgf*cm, 13 ft.*lbf }
Engage the 4 clamps to connect the engine wire to the battery carrier.

INSTALL BATTERY TRAY

Install the battery tray to the battery carrier.

INSTALL BATTERY

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

Torque:

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

Tech Tips

Engage the hook of the battery clamp bolt to the notch of the battery carrier.
Connect the cable to the positive (+) battery terminal and tighten the nut.

Torque:

5.4 N*m { 55 kgf*cm, 48 in.*lbf }
Close the fusible link cover.

INSTALL AIR CLEANER CASE SUB-ASSEMBLY

Install the air cleaner case sub-assembly to the air cleaner bracket with the 2 bolts.

Torque:

7.8 N*m { 80 kgf*cm, 69 in.*lbf }
Engage the clamp to connect the engine wire to the air cleaner case sub-assembly.

INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

Install the air cleaner filter element sub-assembly to the air cleaner case sub-assembly.

INSTALL AIR CLEANER CAP SUB-ASSEMBLY

Engage the 2 guides to install the air cleaner cap sub-assembly to the air cleaner case sub-assembly.
Engage the 2 clamps of the air cleaner cap sub-assembly.
Engage the 2 clamps to connect the engine wire to the air cleaner cap sub-assembly.
Connect the mass air flow meter connector.

INSTALL AIR CLEANER HOSE ASSEMBLY

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CONNECT NO. 1 AIR HOSE (for CVT)

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CONNECT NO. 2 VACUUM SWITCHING VALVE ASSEMBLY (for CVT)

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CONNECT NO. 2 VENTILATION HOSE

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INSTALL OUTER COWL TOP PANEL

for LHD:

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for RHD:

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INSTALL INNER COWL TOP TO COWL BRACE

for LHD:

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for RHD:

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INSTALL FRONT NO. 1 VENTILATOR SEAL

for LHD:

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for RHD:

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INSTALL FRONT AIR SHUTTER SEAL RH

for LHD:

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for RHD:

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INSTALL WINDSHIELD WIPER MOTOR AND LINK

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INSTALL FRONT DRIVE SHAFT ASSEMBLY

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INSTALL FRONT EXHAUST PIPE ASSEMBLY

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

Free Length of Compression Spring
Compression Spring	Standard Free Length	Minimum Free 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 free length is less than the minimum, replace the compression spring.

Insert a new exhaust pipe gasket to the exhaust manifold converter sub-assembly as far as possible by hand.

*1	Exhaust Pipe Gasket
*2	Exhaust Manifold Converter Sub-assembly
*a	Wooden Block
*b	Plastic Hammer

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

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.

Insert a new exhaust pipe gasket to the front exhaust pipe assembly as far as possible by hand.

*1	Exhaust Pipe Gasket
*2	Front Exhaust Pipe Assembly
*a	Wooden Block
*b	Plastic Hammer

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

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 tail exhaust pipe assembly when connecting it.

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

*1	Exhaust Manifold Converter Sub-assembly
*2	Front Exhaust Pipe Assembly
*3	Exhaust Pipe Gasket
*a	Space between flanges: 8.5 mm (0.335 in.)

Connect the front exhaust pipe assembly to the exhaust manifold converter sub-assembly with the 2 compression springs and 2 bolts.

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

Tech Tips

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

*1	Front Exhaust Pipe Assembly
*2	Tail Exhaust Pipe Assembly
*3	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 }

Tech Tips

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