ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

Note

When the manual transaxle is removed, be sure to use a new clutch release with bearing cylinder assembly and new installation bolts. Removal of the manual transaxle allows the compressed clutch release with bearing cylinder assembly to return to its original position, and dust could damage the seal of the clutch release with bearing cylinder assembly, possibly causing clutch fluid leaks.

PROCEDURE


  1. INSTALL ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. B004673C03
      *a Temporarily Tighten

      Temporarily install the engine mounting insulator LH to the vehicle.

    2. Install the 5 bolts in the order shown in the illustration.

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

  2. INSTALL GENERATOR ASSEMBLY

    Click here

  3. INSTALL ENGINE HANGER

    Click here

  4. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND


    1. 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.

    2. Remove the engine assembly from the engine stand.

  5. INSTALL FLYWHEEL SUB-ASSEMBLY

    Click here

  6. INSTALL CLUTCH DISC ASSEMBLY

    Click here

  7. INSTALL CLUTCH COVER ASSEMBLY

    Click here

  8. INSTALL MANUAL TRANSAXLE ASSEMBLY

    Click here

  9. INSTALL FLYWHEEL HOUSING SIDE COVER


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

  10. INSTALL STARTER ASSEMBLY

    Click here

  11. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine assembly with transaxle.

  12. REMOVE ENGINE HANGER


    1. Remove the bolt and engine hanger.

  13. INSTALL WIRE HARNESS CLAMP BRACKET


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

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Engage the 2 clamps.

  14. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    1. Set the engine assembly with transaxle on an engine lifter.

      Note

      Place height adjustment attachments and plate lift attachments under the engine assembly with transaxle.

    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.

      CAUTION:

      Do not raise the engine assembly with transaxle more than necessary. If the engine assembly with transaxle 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.

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

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

      Tech Tips

      When tightening the through bolt, keep the nut from rotating.

    4. B0047AVN04

      Install the engine mounting insulator sub-assembly RH with the 5 bolts and 2 nuts.

      Torque:
      Bolt, nut A
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }
      Bolt, nut B
      88 N*m  { 897 kgf*cm, 65 ft.*lbf }

    5. Install the engine mounting stay with the 2 bolts.

      Torque:
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }

    6. Temporarily install the front suspension crossmember sub-assembly to the vehicle with the 4 bolts.

      B0045JEC06
      *a Datum holes *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 }

  15. INSTALL FRONT SUSPENSION MEMBER BRACE SUB-ASSEMBLY

    Click here

  16. CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  17. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY

    Click here

  18. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  19. INSTALL DRIVE SHAFT ASSEMBLY

    Click here

  20. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  21. INSTALL REAR CONSOLE BOX ASSEMBLY

    Click here

  22. INSTALL FRONT FLOOR CENTER BRACE

    Click here

  23. INSTALL COMPRESSOR WITH PULLEY ASSEMBLY

    Click here

  24. CONNECT INLET HEATER WATER HOSE


    1. Connect the inlet heater water hose to the air conditioner unit assembly and slide the clip to secure it.

  25. CONNECT OUTLET HEATER WATER HOSE


    1. Connect the outlet heater water hose to air conditioner unit assembly and slide the clip to secure it.

  26. CONNECT UNION TO CHECK VALVE HOSE


    1. Connect the union to check valve hose to the air tube and slide the clip to secure it.

  27. INSTALL NO. 1 FUEL VAPOR FEED HOSE


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

  28. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. Connect the fuel tube connector and fuel pipe.

      CAUTION:

      Align the fuel tube connector with the fuel pipe, then push the fuel tube connector in until the retainer makes a "click" sound. If the connection is tight, apply a small amount of engine oil to the tip of the fuel pipe. After connecting, pull the fuel pipe and fuel tube connector to make sure that they are securely connected.

    2. Engage the claw and install the No. 1 fuel pipe clamp.

  29. CONNECT CLUTCH HOSE

    Click here

  30. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    Click here

  31. CONNECT RADIATOR HOSE


    1. Connect the radiator hose to the water inlet and slide the clip to secure it.

  32. CONNECT RESERVE TANK OUTLET HOSE

    Click here

  33. CONNECT RESERVE TANK INLET HOSE


    1. Connect the reserve tank inlet hose to the intercooler reserve tank assembly and slide the clip to secure it.

  34. CONNECT NO. 7 SUB-RADIATOR HOSE

    Click here

  35. CONNECT NO. 4 SUB-RADIATOR HOSE

    Click here

  36. CONNECT NO. 3 RADIATOR HOSE


    1. Connect the No. 3 radiator hose to the cylinder head sub-assembly and slide the clip to secure it.

  37. INSTALL FAN AND GENERATOR V BELT

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  38. INSPECT FAN AND GENERATOR V BELT

    Click here

  39. CONNECT WIRE HARNESS


    1. Connect all the wire harnesses and connectors.

    2. Install the bolt and connect the 2 wire harness clamp to the manual transaxle assembly.

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

    3. Connect the 2 wire harness connectors to the positive (+) battery terminal.

    4. Engage the 2 claws and wire harness to the engine room relay block and junction block assembly.

    5. Connect the 2 wire harness connectors and wire harness to the engine room relay block and junction block assembly.

    6. Connect the wire harness clamp.

    7. Install the No. 1 engine room relay block cover to the engine room relay block and junction block assembly.

    8. Connect the wire harness clamp.

    9. Pull down the lever to connect the 2 ECM connectors.

    10. Connect the clamp and wire harness to the air cleaner blacket.

  40. INSTALL BATTERY CARRIER


    1. Install the battery carrier with the 5 bolts.

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

    2. Connect the 6 wire harness clamps to the battery carrier.

  41. INSTALL BATTERY TRAY


    1. Install the battery tray to the battery carrier.

  42. INSTALL BATTERY


    1. Install the battery.

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

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

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

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

  43. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


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

      Torque:
      7.8 N*m  { 80 kgf*cm, 69 in.*lbf }

    2. Connect the wire harness clamp to the air cleaner case sub-assembly.

  44. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


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

  45. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

    Click here

  46. INSTALL FRONT SUSPENSION UPPER CENTER BRACE SUB-ASSEMBLY


    1. Install the front suspension upper center brace sub-assembly to the front suspension upper to cowl brace bracket LH and front suspension upper to cowl brace bracket RH with the 4 nuts.

      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

  47. INSTALL OUTER COWL TOP PANEL


  48. INSTALL INNER COWL TOP TO COWL BRACE


  49. INSTALL FRONT AIR SHUTTER SEAL RH


  50. INSTALL FRONT NO. 1 VENTILATOR SEAL


  51. INSTALL WINDSHIELD WIPER LINK ASSEMBLY

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  52. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


    1. Connect the cable to the 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

  53. ADD MANUAL TRANSAXLE OIL

    Click here

  54. ADJUST TRANSMISSION CONTROL SELECT CABLE

    Click here

  55. ADD ENGINE COOLANT

    Click here

  56. ADD ENGINE COOLANT (for Intercooler)

    Click here

  57. ADD ENGINE OIL

    Click here

  58. CHECK ENGINE OIL LEVEL

    Click here

  59. INSPECT FOR FUEL LEAK

    Click here

  60. INSPECT FOR COOLANT LEAK

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  61. INSPECT FOR COOLANT LEAK (for Intercooler)

    Click here

  62. INSPECT FOR OIL LEAK

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  63. INSPECT FOR EXHAUST GAS LEAK

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  64. INSTALL ENGINE UNDER COVER RH


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

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

  65. 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, 4 ft.*lbf }

  66. BLEED CLUTCH LINE

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  67. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

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  68. WARM UP ENGINE

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  69. INSPECT FOR REFRIGERANT LEAK

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  70. INSTALL FRONT WHEELS

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

  71. INSPECT ENGINE IDLE SPEED

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  72. INSPECT CO/HC

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  73. ADJUST FRONT WHEEL ALIGNMENT

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  74. INSPECT FOR SPEED SENSOR SIGNAL

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