ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

PROCEDURE

1. Click here

   INSTALL INNER OIL SEAL (w/ Stop And Start System)

   Click here

2. Click here

   INSTALL RING GEAR SUB-ASSEMBLY (w/ Stop And Start System)

   Click here

3. Click here

   REMOVE RING GEAR SNAP RING (w/ Stop And Start System)

   Click here

4. Click here

   INSTALL ERS ONE-WAY CLUTCH ASSEMBLY (w/ Stop And Start System)

   Click here

5. Click here

   INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (w/ Stop And Start System)

   Click here

6. Click here

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

   Click here

7. Click here

   INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)

   Click here

8. Click here

   INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)

   Click here

9. Click here

   INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)

   Click here

10. Click here

    INSTALL WATER HOSE SUB-ASSEMBLY B (for Manual Transaxle)

    
    

    1. Install the water hose sub-assembly B with the clamp.

11. Click here

    INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY (for CVT)

    
    

    1. Install the No. 2 water by-pass pipe hose sub-assembly with the clamp.

12. Click here

    INSTALL WATER HOSE SUB-ASSEMBLY

    
    

    1. Install the water hose sub-assembly with the clamp.

13. Click here

    INSTALL ENGINE WIRE

    
    

    1. Install the engine wire to the cylinder head cover with the 2 nuts.

       8.4 N*m

       86 kgf*cm

       74 in.*lbf

    2. Install the 2 ground wires to the cylinder head with the 2 bolts.

       8.4 N*m

       86 kgf*cm

       74 in.*lbf

14. Click here

    REMOVE ENGINE HANGER

    
    

    1. Remove the 2 bolts and 2 engine hangers.

15. Click here

    INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

    (Click here)

16. Click here

    INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY (for CVT)

    (Click here)

17. Click here

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

    Click here

18. Click here

    INSTALL STARTER ASSEMBLY (w/ Stop And Start System)

    Click here

19. Click here

    INSTALL STARTER ASSEMBLY (w/o Stop And Start System)

    Click here

20. Click here

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

    Click here

21. Click here

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

    Click here

22. Click here

    INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    
    

    1. Install the engine mounting insulator sub-assembly RH with the 3 bolts.

       Tip:

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

       52 N*m

       530 kgf*cm

       38 ft.*lbf

    2. Install the engine mounting insulator LH with the 5 bolts.

       Tip:

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

       52 N*m

       530 kgf*cm

       38 ft.*lbf

    3. Set the engine assembly with transaxle on the engine lifter.

    4. Operate the engine lifter and lift the engine assembly with transaxle into 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 is clear of all wiring and hoses.

       
       

       • While raising the engine into the vehicle, do not allow it to contact the vehicle.

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

       52 N*m

       530 kgf*cm

       38 ft.*lbf

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

       52 N*m

       530 kgf*cm

       38 ft.*lbf

    7. 

       Provisionally install the front suspension crossmember onto the body with the 6 bolts.

       Table 1. Text in Illustration

       *a	Datum Hole	-	-
       	Front of the Vehicle	-	-

    8. 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.

       09670-00010

       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 in a vertical orientation.

       • If SST cannot be inserted into the datum hole vertically, loosen all the bolts and then insert SST again.

    9. 

       Tighten the bolt and install the engine moving control rod.

       120 N*m

       1224 kgf*cm

       89 ft.*lbf

23. Click here

    INSTALL WIRE HARNESS CLAMP BRACKET (for Manual Transaxle)

    
    

    1. Install wire harness clamp bracket with the bolt.

       29 N*m

       296 kgf*cm

       21 ft.*lbf

24. Click here

    INSTALL WIRE HARNESS CLAMP BRACKET (for CVT)

    
    

    1. Install wire harness clamp bracket with the bolt.

       61 N*m

       622 kgf*cm

       45 ft.*lbf

25. Click here

    INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

    
    

    1. Install the drive shaft heat insulator sub-assembly with the 2 bolts.

       24 N*m

       240 kgf*cm

       17 ft.*lbf

26. Click here

    INSTALL FRONT EXHAUST PIPE ASSEMBLY

    
    
    1. 

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

       Minimum length
       41.5 mm (1.634 in.)

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

    2. 

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

       Table 2. Text in Illustration

       *1	Gasket
       *2	Wooden Block
       *3	Plastic Hammer
       *4	Exhaust Manifold Converter Sub-assembly

       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 its.

    3. Hang the front exhaust pipe assembly with the 3 exhaust pipe supports.

    4. 

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

       43 N*m

       438 kgf*cm

       32 ft.*lbf

       Note:

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

       Table 3. Text in Illustration

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

    5. Hang the tail exhaust pipe assembly with the exhaust pipe support.

    6. Install a new gasket onto the front exhaust pipe sub-assembly.

    7. Install the tail exhaust pipe assembly onto the front exhaust pipe sub-assembly with the 2 compression springs and 2 bolts.

       19 N*m

       194 kgf*cm

       14 ft.*lbf

    8. Connect the connector of the heated oxygen sensor.

    9. Engage the clamp and connect the heated oxygen sensor wire to the wire harness clamp bracket.

27. Click here

    INSTALL FRONT FLOOR CENTER BRACE

    Click here

28. Click here

    INSTALL FRONT DRIVE SHAFT ASSEMBLY

    (Click here)

29. Click here

    INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

30. Click here

    INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY

    Click here

31. Click here

    INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

32. Click here

    CONNECT ENGINE WIRE (for Manual Transaxle)

    
    

    1. Connect the connector to the negative battery terminal.

    2. Connect the 2 connectors to the positive battery terminal.

    3. Install the ground wire to the body with the bolt.

       8.4 N*m

       86 kgf*cm

       74 in.*lbf

    4. Engage the 3 clamps and connect the connector to the engine room relay block.

    5. Install the engine room relay block cover.

    6. Check that the engine wire is connected between the body and engine assembly with transaxle.

33. Click here

    CONNECT ENGINE WIRE (for CVT)

    
    

    1. Connect the connector to the negative battery terminal.

    2. Connect the 2 connectors to the positive battery terminal.

    3. Install the ground wire to the body with the bolt.

       8.4 N*m

       86 kgf*cm

       74 in.*lbf

    4. Engage the 3 clamps and connect the 2 connectors to the engine room relay block.

    5. Install the engine room relay block cover.

    6. Check that the engine wire is connected between the body and engine assembly with transaxle.

34. Click here

    CONNECT ECM CONNECTOR (for LHD)

    
    
    1. 

       Pull down the lever to engage the lock and connect the connector to the ECM.

       Note:

       Make sure that the levers are securely locked.

    2. Engage the clamp and install the engine wire.

35. Click here

    CONNECT ECM CONNECTOR (for RHD)

    
    
    1. 

       Pull down the lever to engage the lock and connect the connector to the ECM.

       Note:

       Make sure that the levers are securely locked.

36. Click here

    INSTALL COMPRESSOR ASSEMBLY WITH PULLEY (for TMC Made)

    Click here

37. Click here

    INSTALL COMPRESSOR ASSEMBLY WITH PULLEY (for TMMF Made)

    Click here

38. Click here

    INSTALL CLUTCH HOSE (for Manual Transaxle)

    Click here

39. Click here

    CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)

    Click here

40. Click here

    INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for CVT)

    Click here

41. Click here

    CONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

42. Click here

    INSTALL EFI FUEL PIPE CLAMP

    Click here

43. Click here

    CONNECT WATER HOSE SUB-ASSEMBLY (for TMC Made)

    Click here

44. Click here

    CONNECT WATER HOSE SUB-ASSEMBLY B (for TMC Made)

    Click here

45. Click here

    CONNECT WATER HOSE SUB-ASSEMBLY (for TMMF Made)

    Click here

46. Click here

    CONNECT WATER HOSE SUB-ASSEMBLY B (for TMMF Made)

    Click here

47. Click here

    CONNECT NO. 2 RADIATOR HOSE

    
    
    1. 

       Connect the No. 2 radiator hose with the clamp.

       Table 4. Text in Illustration

       *a	View A
       *b	Upper Side

48. Click here

    CONNECT NO. 1 RADIATOR HOSE

    
    
    1. 

       Connect the No. 1 radiator hose with the clamp.

       Table 5. Text in Illustration

       *a	View A
       *b	Upper Side
       *c	Rear Side

49. Click here

    CONNECT NO. 1 BREATHER PLUG (for CVT)

    
    

    1. Connect the No. 1 breather plug.

50. Click here

    CONNECT UNION TO CONNECTOR TUBE HOSE

    
    

    1. Connect the union to connector tube hose to the intake manifold.

51. Click here

    INSTALL AIR CLEANER AND HOSE ASSEMBLY

    
    

    1. Connect the air cleaner hose to the throttle body.

    2. Connect the No. 2 ventilation hose to the air cleaner hose.

    3. Connect the No. 1 fuel vapor feed hose and the No. 2 fuel vapor feed hose to the No. 1 vacuum switching valve assembly.

    4. Connect the No. 1 vacuum switching valve assembly connector and engage the clamp.

    5. Install the air cleaner case to the cylinder head cover with the 2 bolts.

       7.8 N*m

       80 kgf*cm

       69 in.*lbf

    6. Connect the intake mass air flow meter connector and engage the clamp.

52. Click here

    INSTALL BATTERY CARRIER

    
    

    1. Install the battery carrier with the 5 bolts.

       17 N*m

       173 kgf*cm

       13 ft.*lbf

    2. Engage the 3 clamps and connect the wire harness to the battery carrier.

53. Click here

    INSTALL BATTERY TRAY

    
    

    1. Install the battery tray to the battery carrier.

54. Click here

    INSTALL BATTERY

    
    

    1. Install the battery to the battery tray.

    2. Install the battery carrier clamp with the nut.

       3.5 N*m

       36 kgf*cm

       31 in.*lbf

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

       5.4 N*m

       55 kgf*cm

       48 in.*lbf

55. Click here

    INSTALL GENERATOR ASSEMBLY (for 80A Type)

    (Click here)

56. Click here

    INSTALL GENERATOR ASSEMBLY (for 100A Type)

    (Click here)

57. Click here

    INSTALL OUTER COWL TOP PANEL

    Click here

58. Click here

    INSTALL INNER COWL TOP TO COWL BRACE

    Click here

59. Click here

    INSTALL FRONT NO. 1 VENTILATOR SEAL

    Click here

60. Click here

    INSTALL FRONT AIR SHUTTER SEAL RH

    Click here

61. Click here

    INSTALL WINDSHIELD WIPER LINK ASSEMBLY

    (Click here)

62. Click here

    INSTALL FRONT WHEELS

    103 N*m

    1050 kgf*cm

    76 ft.*lbf

63. Click here

    CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    5.4 N*m

    55 kgf*cm

    48 in.*lbf

64. Click here

    INSPECT SHIFT LEVER POSITION (for CVT)

    Click here

65. Click here

    ADJUST SHIFT LEVER POSITION (for CVT)

    Click here

66. Click here

    INSTALL REAR CONSOLE BOX ASSEMBLY (for CVT)

    (Click here)

67. Click here

    ADD ENGINE OIL

    Click here

68. Click here

    ADD ENGINE COOLANT

    Click here

69. Click here

    ADD CONTINUOUSLY VARIABLE TRANSAXLE FLUID (for CVT)

    (Click here)

70. Click here

    ADD MANUAL TRANSAXLE OIL (for Manual Transaxle)

    Click here

71. Click here

    BLEED CLUTCH PIPE LINE (for Manual Transmission)

    (Click here)

72. Click here

    INSPECT CONTINUOUSLY VARIABLE TRANSAXLE FLUID (for CVT)

    Click here

73. Click here

    INSPECT FOR FUEL LEAK

    Click here

74. Click here

    INSPECT ENGINE OIL LEVEL

    Click here

75. Click here

    INSPECT FOR ENGINE OIL LEAK

76. Click here

    INSPECT FOR ENGINE COOLANT LEAK

    Click here

77. Click here

    INSPECT RESERVOIR TANK ENGINE COOLANT LEVEL

    Click here

78. Click here

    INSPECT CONTINUOUSLY VARIABLE TRANSAXLE FLUID LEAK (for CVT)

79. Click here

    INSPECT MANUAL TRANSAXLE OIL LEAK (for Manual Transaxle)

80. Click here

    INSPECT FOR CLUTCH FLUID LEAK (for Manual Transmission)

81. Click here

    INSPECT FOR EXHAUST GAS LEAK

    Tip:

    Perform "Inspection After Repairs" after repairing gas leaks in the exhaust system (Click here).

82. Click here

    INSPECT IGNITION TIMING

    Click here

83. Click here

    INSPECT ENGINE IDLING SPEED

    Click here

84. Click here

    INSPECT CO/HC

    Click here

85. Click here

    INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    (Click here)

86. Click here

    INSTALL ENGINE UNDER COVER RH

    5.0 N*m

    51 kgf*cm

    44 in.*lbf

87. Click here

    INSTALL ENGINE UNDER COVER LH

    5.0 N*m

    51 kgf*cm

    44 in.*lbf

88. Click here

    CHECK ABS SENSOR SIGNAL (w/o VSC)

    (Click here)

89. Click here

    CHECK VSC SENSOR SIGNAL (w/ VSC)

    Tip:
    

    • for TMC Made (Click here)

    • for TMMF Made (Click here)