ENGINE ASSEMBLY INSTALLATION


  1. INSTALL CRANKSHAFT PULLEY


    1. Install the crankshaft timing pulley and key.

    2. A01386OE01

      Install crankshaft pulley with the bolt.

    3. Using SST, hold the crankshaft.

      SST
      09330-00021

    4. Tighten the bolt.

      Torque:
      35 N*m  { 357 kgf*cm, 22 ft.*lbf }
    5. A0136QPE01

      Mark the top surface of the crankshaft pulley bolt with paint.

    6. Retighten the bolt by an additional 190 degrees as shown in the illustration.

  2. INSTALL FLYWHEEL SUB-ASSEMBLY


    1. A0137WYE01

      Using SST, hold the crankshaft pulley.

      SST
      09330-00021

    2. Apply adhesive to 2 or 3 threads of the bolt end.

      Adhesive
      Part No. 08833-00070, THREE BOND 1324 or equivalent
    3. A01367IE01

      Install the flywheel sub-assembly with the 6 bolts.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

      Note

      Tighten the bolts in the order shown in the illustration.

    4. A01366QE01

      Mark the top surfaces of the flywheel bolts with paint.

    5. Retighten the bolts by an additional 70 degrees as shown in the illustration.

  3. REMOVE CRANKSHAFT PULLEY


    1. A0137WYE01

      Using SST, hold the crankshaft pulley.

      SST
      09330-00021

    2. Remove the bolt and crankshaft pulley.

  4. INSTALL CLUTCH DISC ASSEMBLY

    A0136R3E01

    1. Insert SST into the clutch disc, and then insert them into the flywheel.

      SST
      09301-00131

      Note

      Do not insert the clutch disc in the wrong direction.

  5. INSTALL CLUTCH COVER ASSEMBLY

    A0137J5E01

    1. Align the matchmark on the clutch cover with the one on the flywheel.

    2. Tighten the 6 bolts uniformly in the order shown in the illustration, starting with the bolt located near the knock pin on the top.

      Torque:
      19 N*m  { 195 kgf*cm, 14 ft.*lbf }

      Tech Tips

      After checking that the disc is in the center, gently move SST up and down, right and left to tighten the bolts.

      SST
      09301-00131

  6. INSTALL MANUAL TRANSAXLE ASSEMBLY


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

    2. A01373ME01

      Install the 7 bolts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Tech Tips


      • Install 3 A bolts from the transaxle side.

      • Install 4 B bolts from the engine side.

  7. INSTALL STARTER ASSEMBLY


    1. A0138HDE02

      Using a hexagon wrench (6 mm), install the starter with the 3 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    2. Connect the wire harness to terminal 30 and install the nut.

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

    3. Connect the wire harness to terminal 50 and install the nut.

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

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

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  8. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. A01389H

      Install the engine with transaxle assembly to the crossmember sub-assembly and the engine mounting member with the bolt.

      Torque:
      120 N*m  { 1,224 kgf*cm, 89 ft.*lbf }

    2. Set the engine lifter.

    3. A0136HV

      Remove the chain block from the engine assembly with transaxle.

  9. REMOVE ENGINE MOUNT BRACKET


    1. A0138R6

      Remove the 4 bolts and engine mount bracket.

  10. INSTALL INJECTION OR SUPPLY PUMP ASSEMBLY


    1. A013885

      Install the injection pump with the 3 bolts.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }
    2. A01388JE01

      Install the injection pump support.

      Torque:
      For A
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      For B
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      For C
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    3. A01393GE01

      Using SST, install the injection pump drive pulley with the nut.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
      Torque:
      50 N*m  { 510 kgf*cm, 37 ft.*lbf }

  11. SET TIMING MARK


    1. A0136QE

      Using SST, set the pulley of the camshaft so that the timing holes of the camshaft drive pulley and the cylinder head are aligned.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
    2. A0137Z1

      Using the crankshaft pulley bolt, turn the crankshaft so that the timing holes of the crankshaft timing pulley and the oil pump are aligned.

  12. INSTALL TIMING BELT


    1. A0138L6

      Temporarily install the timing belt tensioner with the bolt.

    2. Install the timing belt.

    3. A013842

      Check that the timing holes are aligned as shown in the illustration.

    4. A0137ALE01

      Using a hexagon socket wrench, turn the timing belt tensioner as shown in the illustration.

      Tech Tips

      Part A should be positioned within area B.

    5. Tighten the timing belt tensioner bolt.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  13. CHECK VALVE TIMING


    1. A013842

      Slowly turn the crankshaft 2 complete revolutions (720°).

    2. Check that the timing holes are aligned as shown in the illustration.

    3. Remove the crankshaft pulley bolt.

  14. INSTALL CRANKSHAFT POSITION SENSOR


    1. A0136ZP

      Install the crankshaft timing pulley support with the bolt.

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

    2. Install the crankshaft position sensor with the bolt.

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

    3. Connect the crankshaft position sensor connector.

  15. INSTALL ENGINE MOUNT BRACKET


    1. A01374V

      Install the engine mount bracket with the 4 bolts.

      Torque:
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }

  16. INSTALL TIMING BELT LOWER COVER


    1. A0135SJ

      Install the timing belt lower cover with the 5 bolts.

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

  17. INSTALL CRANKSHAFT PULLEY


    1. A0136NUE01

      Temporarily install the timing belt tensioner with the bolt.

    2. Using SST, hold the crankshaft pulley.

      SST
      09330-00021

    3. Tighten the bolt.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
    4. A0136QPE01

      Mark the top surface of the crankshaft pulley bolt with paint.

    5. Retighten the bolt by an additional 190 degrees as shown in the illustration.

  18. INSTALL INJECTOR ASSEMBLY

    CAUTION:

    Do not reuse the nozzle seat . If the injector has been removed, be sure to replace the nozzle seat with a new one.


    1. A01372C

      Install 4 new nozzle seats to the cylinder head.

    2. Install the 4 collars to the cylinder head.

    3. Install the 4 shims to the cylinder head.

    4. Install the 4 injectors to the cylinder head.

    5. Temporarily, install the 4 nozzle holder clamps with the 4 bolts.

    6. A0138PR

      Temporarily, install the common rail assembly with the 2 bolts.

    7. A0137LCE01

      Temporarily install new injection pipes No.1, No.2, No.3 and No.4.

    8. Using SST, tighten the nut of the 4 injection pipes on the common rail side.

      SST
      09023-12701
      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

      Tech Tips

      Use a torque wrench with a fulcrum length 30 cm (11.81 in.).

    9. Using SST, retighten the nut of the 4 injection pipes on the common rail side.

      Torque:
      23 N*m  { 232 kgf*cm, 17 ft.*lbf }

      Tech Tips

      Use a torque wrench with a fulcrum length 30 cm (11.81 in.).

    10. Using SST, tighten the nut of the 4 injection pipes on the injector side.

      SST
      09023-38401
      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

      Tech Tips

      Use a torque wrench with a fulcrum length 30 cm (11.81 in.).

    11. Using SST, retighten the nut of the 4 injection pipes on the injector side.

      Torque:
      23 N*m  { 232 kgf*cm, 17 ft.*lbf }

      Tech Tips

      Use a torque wrench with a fulcrum length 30 cm (11.81 in.).

    12. A0137J9E01

      Temporarily install a new fuel inlet pipe.

    13. Using SST, tighten the nut of the fuel inlet pipe on the common rail side.

      SST
      09023-12701
      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

      Tech Tips

      Use a torque wrench with a fulcrum length 30 cm (11.81 in.).

    14. Using SST, retighten the nut of the fuel inlet pipe on the common rail side.

      Torque:
      23 N*m  { 232 kgf*cm, 17 ft.*lbf }

      Tech Tips

      Use a torque wrench with a fulcrum length 30 cm (11.81 in.).

    15. Using SST, tighten the nut of the fuel inlet pipe on the fuel pump side.

      SST
      09023-38401
      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

      Tech Tips

      Use a torque wrench with a fulcrum length 30 cm (11.81 in.).

    16. Using SST, retighten the nut of the fuel inlet pipe on the fuel pump side.

      Torque:
      23 N*m  { 232 kgf*cm, 17 ft.*lbf }

      Tech Tips

      Use a torque wrench with a fulcrum length 30 cm (11.81 in.).

    17. A0137GE

      Tighten the 2 bolts to the common rail.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

    18. Tighten the 4 bolts to the nozzle holder clamps.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  19. INSTALL GLOW PLUG ASSEMBLY


    1. A01381G

      Install the 4 glow plugs.

      Torque:
      8.5 N*m  { 87 kgf*cm, 73 in.*lbf }

  20. INSTALL GLOW PLUG HARNESS


    1. A01366E

      Install the glow harness with the 4 bolts.

      Torque:
      1.2 N*m  { 12 kgf*cm, 11 in.*lbf }

  21. INSTALL CAMSHAFT POSITION SENSOR

    Tech Tips


    • Install new camshaft position sensor Click here.

    • Install reused camshaft position sensor Click here.

  22. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. Install a new gasket to the engine oil pressure switch assembly.

    2. A0138NV

      Install the engine oil pressure switch assembly.

      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }
    3. A0137DB

      Connect the engine oil pressure switch connector.

  23. INSTALL VACUUM PUMP ASSEMBLY


    1. Install 2 new O-rings to the vacuum pump assembly.

    2. A0136AU

      Install the vacuum pump assembly with the 2 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  24. INSTALL EXHAUST MANIFOLD


    1. A01365E

      Install the gasket, exhaust manifold and 10 collars with the 10 nuts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  25. INSTALL TURBOCHARGER SUB-ASSEMBLY


    1. A0138BX

      Install the turbocharger sub-assembly with the 4 nuts.

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

  26. INSTALL TURBOCHARGER LUBRICATING PIPE


    1. A0137C6

      Using a hexagon socket wrench, install the turbocharger lubricating pipe and 4 new gaskets with the 2 union bolts.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

  27. INSTALL OIL COOLER ASSEMBLY


    1. Install 2 new gaskets to the oil cooler assembly.

    2. A01379R

      Install the oil cooler assembly with the 4 bolts.

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

  28. INSTALL LUBRICATION RETURN HOSE


    1. A0137F0

      Temporarily install the lubrication return hose with the 2 clamps.

    2. Tighten the 2 clamps.

      Torque:
      3.0 N*m  { 31 kgf*cm, 27 in.*lbf }

  29. INSTALL V-RIBBED BELT TENSIONER SUB-ASSEMBLY


    1. A0137H7

      Install the V-ribbed belt tensioner sub-assembly with the 3 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  30. INSTALL ALTERNATOR BRACKET NO.2 (w/ Air Conditioning System)


    1. A0137KY

      Install the alternator bracket No.2 with the 2 bolts and 2 nuts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  31. INSTALL ALTERNATOR BRACKET NO.2 (w/o Air Conditioning System)


    1. A013846

      Install the alternator bracket No.2 with the 2 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  32. INSTALL V-RIBBED BELT IDLER ASSEMBLY NO.1 (w/o Air Conditioning System)


    1. A0137NR

      Using a hexagon socket wrench, install the V-ribbed belt idler assembly No.1 with the bolt.

      Torque:
      48 N*m  { 490 kgf*cm, 35 ft.*lbf }

  33. INSTALL ALTERNATOR BRACKET NO.1


    1. A0137JK

      Install the alternator bracket No.1 with the 4 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  34. INSTALL GENERATOR ASSEMBLY


    1. A0137E9E02

      Install the generator assembly with the 4 bolts.

      Torque:
      Bolt A
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }
      Bolt B
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }

    2. Install the generator wire to terminal B with the nut.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

    3. Install the terminal cap.

    4. Connect the generator connector.

  35. INSTALL OIL LEVEL GAUGE GUIDE


    1. A013776

      Install 2 new O-rings to the oil level gauge guide.

    2. A0137BX

      Install the oil level gauge guide with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  36. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY


    1. Install the oil level gauge.

  37. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. A0136EB

      Temporarily install the exhaust manifold converter clamp, converter separator insulator No.1, catalytic converter support bracket, exhaust manifold converter sub-assembly and 2 nuts.

    2. Tighten the 2 nuts to the cylinder block.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    3. Retighten the 2 nuts to the cylinder block.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    4. Tighten the nut of the exhaust manifold converter clamp.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  38. INSTALL MANIFOLD HEAT SHIELD


    1. A0138LO

      Install the manifold heat shield with the 2 bolts.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  39. INSTALL TURBO INSULATOR NO.1


    1. A0137BH

      Install the turbo insulator No.1 with the 7 bolts.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

  40. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A0136DLE01

      Install 4 new O-rings and a gasket to the cylinder head cover.

    2. Temporarily install the cylinder head cover with the 10 bolts.

    3. Tighten the 10 bolts in the order shown in the illustration.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    4. A013789

      Connect the diesel throttle valve connector.

  41. INSTALL EGR VALVE ASSEMBLY


    1. Install a new O-ring to the EGR pipe.

    2. Temporarily install the EGR valve assembly and gasket with the 2 screws and 2 bolts.

    3. A0136D4

      Install the clamp with the bolt.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }
    4. A01369N

      Tighten the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    5. A0137SF

      Using a "torx" socket wrench, tighten the 2 screws.

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

  42. INSTALL WATER OUTLET BOX


    1. Install a new O-ring to the water outlet box.

    2. Install a new gasket to the thermostat housing.

    3. Temporarily install the water outlet box and thermostat housing with the 6 bolts.

    4. A01360X

      Tighten the 2 bolts to the water outlet box.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    5. A0138HX

      Tighten the 4 bolts to the thermostat housing.

      Torque:
      3.0 N*m  { 31 kgf*cm, 27 in.*lbf }

    6. Retighten the 4 bolts to the thermostat housing side.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  43. INSTALL EGR COOLER WATER BY-PASS HOSE


    1. A0137WQ

      Using pliers, slide the 2 clips to install the water by-pass hose.

  44. INSTALL HEATER WATER OUTLET HOSE A


    1. A0137MH

      Using pliers, slide the clip to install the heater water outlet hose A.

  45. INSTALL HEATER WATER INLET HOSE A


    1. A0137S1

      Using pliers, slide the clip to install the water inlet hose A.

  46. INSTALL WATER BY-PASS HOSE NO.5


    1. A01390T

      Install the water by-pass hose No.5 with the bolt.

    2. Using pliers, slide the clip to connect the water by-pass hose.

  47. INSTALL ENGINE WIRE NO.2


    1. A0136C6

      Install the engine wire No.2 to the injector.

      CAUTION:

      Be sure to connect the injector connectors correctly to prevent malfunctions in the injector.

    2. A0135V2

      Connect the fuel pressure sensor connector.

    3. A0138A5

      Connect the glow harness connector.

  48. INSTALL FUEL FILTER ASSEMBLY


    1. A0136XL

      Temporarily install the fuel filter assembly with the 2 bolts and screw.

    2. Tighten the 2 bolts.

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

    3. Using a "torx" socket wrench, tighten the screw.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    4. A01393H

      Connect the fuel heater connector.

    5. A013931

      Connect the fuel level warning switch connector.

    6. A0137IZ

      Align the connector with the pipe, then push in the connector to the pipe until it makes a "click" sound to connect the fuel return hose to the fuel pump return pipe.

    7. Align the connector with the pipe, then push in the connector to the pipe until it makes a "click" sound to connect the fuel hose to the fuel pump pipe.

    8. A0135W0

      Connect the pressure control valve connector.

    9. A0135ZW

      Connect the fuel return hose to the No.4 injector.

  49. CONNECT FUEL FLOW REGULATOR VALVE


    1. A0138SY

      Connect the fuel flow regulator valve.

  50. CONNECT PRESSURE CONTROL VALVE


    1. A0138VC

      Connect the pressure control valve.

  51. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. A0137UK

      Temporarily install the air cleaner case, air hose No.1 clamp and 2 screws.

    2. Using a "torx" socket wrench, tighten the 2 screws.

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

    3. Tighten the air hose No.1 clamp.

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

    4. Connect the PCV hose.

  52. INSTALL TURBO PRESSURE SENSOR


    1. A01362M

      Install the turbo pressure sensor with the bolt.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. A0137YA

      Connect the turbo pressure sensor connector.

    3. A0136M9

      Connect the turbo pressure sensor to the cylinder head cover.

  53. INSTALL INTAKE AIR RESONATOR


    1. A0137XK

      Install a new O-ring to the intake air resonator.

    2. Temporarily install the intake air resonator with the clamp, bolt and screw.

    3. Tighten the bolt.

      Torque:
      7.5 N*m  { 77 kgf*cm, 66 in.*lbf }

    4. Tighten the air hose No.1 clamp.

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

    5. Using a "torx" socket wrench, tighten the screw.

      Torque:
      7.5 N*m  { 77 kgf*cm, 66 in.*lbf }
    6. A0136RX

      Connect the air temperature sensor connector.

  54. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. Install the air filter element.

    2. A0136UU

      Using a "torx" socket wrench, install the air cleaner case sub-assembly with the 3 screws.

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

  55. INSTALL TIMING BELT UPPER COVER


    1. A0138DM

      Install the timing belt upper cover with the 5 bolts.

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

  56. INSTALL ENGINE W/ TRANSAXLE


    1. Install the engine with transaxle.

    2. A01388ME02

      Tighten the 6 bolts.

      Torque:
      For A
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }
      For B
      128 N*m  { 1,306 kgf*cm, 95 ft.*lbf }
      For C
      48 N*m  { 490 kgf*cm, 35 ft.*lbf }
    3. A0136QC

      Tighten the 3 bolts.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }
    4. A01393O

      Tighten the nut.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }
    5. A0136JO

      Tighten the 2 bolts.

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

  57. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

    A0137MQ

    1. Coat the spline of the inboard joint shaft assembly with transaxle oil.

    2. Align the shaft splines and install the drive shaft assembly with a screwdriver and hammer.

      Note


      • Face the snap ring cut area downward.

      • Do not damage the oil seal.

      • Do not damage the front drive shaft assembly boot.

      Tech Tips

      Whether the front drive shaft assembly is securely driven in or not can be confirmed from the brass bar reaction force or sound.

  58. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  59. INSTALL FRONT SUSPENSION LOWER ARM SUB-ASSEMBLY NO.1 LH

    A0136N3

    1. Push the front suspension lower arm No. 1 downward, install the front lower ball joint and tighten the castle nut and a new clip.

      Torque:
      98 N*m  { 1,000 kgf*cm, 72 ft.*lbf }

      Note

      Retighten the castle nut and clip within a turning angle of 60° after aligning the hole of the clip with the castle nut.

  60. INSTALL FRONT SUSPENSION LOWER ARM SUB-ASSEMBLY NO.1 RH

    Tech Tips

    Perform the same procedure as for the LH side.

  61. INSTALL TIE ROD END SUB-ASSEMBLY LH

    A013608

    1. Connect the tie rod end to the steering knuckle and install it with the castle nut and a new cotter pin.

      Torque:
      33 N*m  { 336 kgf*cm, 24 ft.*lbf }

      Note

      Retighten the castle nut and cotter pin within a turning angle of 60° after aligning the hole of the cotter pin with the castle nut.

  62. INSTALL TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  63. INSTALL FRONT AXLE HUB NUT LH

    A0135U4E01

    1. Install a new front axle hub nut.

      Torque:
      216 N*m  { 2,202 kgf*cm, 160 ft.*lbf }

    2. Using a hammer and chisel, stake the front axle hub nut.

  64. INSTALL FRONT AXLE HUB NUT RH

    Tech Tips

    Perform the same procedure as for the LH side.

  65. INSTALL FRONT WHEEL

  66. INSTALL STEERING INTERMEDIATE SHAFT ASSEMBLY NO.2


    1. A0135UXE01

      Align the matchmarks and install the intermediate shaft No. 2 onto the steering link with bolt B.

      Torque:
      35 N*m  { 360 kgf*cm, 26 ft.*lbf }

    2. Tighten bolt A.

      Torque:
      35 N*m  { 360 kgf*cm, 26 ft.*lbf }

  67. INSTALL STEERING COLUMN HOLE COVER PLATE

    A0136Y5

    1. Engage the steering hole plate.

  68. INSTALL CLUTCH RELEASE CABLE ASSEMBLY

    A01391Y

    1. Connect the clutch release cable to the manual transaxle.

  69. ADJUST CLUTCH RELEASE CABLE ASSEMBLY


    1. Turn up the floor carpet.

    2. A0137UAE01

      Check whether the pedal height is correct.

      Pedal height from floor panel
      LHD
      135 to 145 mm (5.31 to 5.71 in.)
      RHD
      161 to 171 mm (6.34 to 6.74 in.)

    3. Adjust the pedal height.


      1. Loosen the lock nut and turn the stopper bolt until the height is correct.

      2. Tighten the lock nut.

        Torque:
        25 N*m  { 250 kgf*cm, 18 ft.*lbf }
    4. A013903E01

      Check that the pedal free play is correct.


      1. Depress the pedal until the resistance begins to be felt.

        Pedal free play
        13 to 23 mm (0.512 to 0.906 in.)
    5. A01391EE01

      Adjust the pedal free play.


      1. Turn the clutch release cable adjusting nut until the pedal free play is correct.

        Note

        Confirm that the clutch cable boot is installed.

      2. After adjusting the pedal free play, check the pedal height.

    6. Check the clutch release point.


      1. Pull the parking brake lever and install the wheel stopper.

      2. Start the engine and allow it to idle.

      3. A0137CGE01

        Without depressing the clutch pedal, slowly adjust the shift lever to the reverse position until the gears come into contact with the clutch pedal.

      4. Gradually depress the clutch pedal and measure the stroke distance from the point that the gear noise stops (release point) up to the full stroke end position.

        Standard distance
        20 mm (0.787 in.) or more (from pedal stroke end position to release point)

        If the distance is not as specified, perform the following operations.


        • Check the pedal height.

        • Check the pedal free play.

        • Check the clutch cover and disc.

        • Check the pedal stroke.

        Pedal stroke
        148 mm (5.83 in.)

  70. INSTALL TRANSAXLE CONTROL CABLE ASSEMBLY

    A0136KNE01

    1. Connect the transmission select cable to the manual transaxle with new clips A and B.

    2. A0135UNE01

      Connect the transmission shift cable to the manual transaxle with new clips A and B.

  71. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. A0137JO

      Align the connector with the pipe, then push in the connector to the pipe until it makes a "click" sound to connect the fuel tube sub-assembly.

  72. INSTALL FUEL FILTER PROTECTOR


    1. A0136I9

      Using a "torx" socket wrench, install the fuel filter protector with the screws.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  73. CONNECT FUEL RETURN TUBE SUB-ASSEMBLY


    1. A0136XW

      Align the connector with the pipe, then push in the connector to the pipe until it makes a "click" sound to connect the fuel return tube sub-assembly to the fuel filter.

  74. CONNECT HEATER WATER OUTLET HOSE A


    1. A0138TX

      Insert the heater water outlet hose A.

    2. Install the clip.

  75. CONNECT HEATER WATER HOSE INLET A


    1. A0136WU

      Using pliers, slide the clip to connect the heater water inlet hose A.

  76. CONNECT VACUUM HOSE ASSEMBLY


    1. A0136S3

      Align the connector with the pipe, then push in the connector to the pipe until it makes a "click" sound to connect the vacuum hose assembly to the vacuum pump.

  77. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)

    Tech Tips

    Click here

  78. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. Install the exhaust front pipe assembly with a new clamp.

      A0137Z8E03
      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    2. Install the exhaust front pipe stay nut and exhaust pipe support No.4.

      Torque:
      7.7 N*m  { 79 kgf*cm, 68 ft.*lbf }

    3. Install a new clamp and bolt.

      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

      Note

      The clamp marks and stampings should be aligned.

  79. INSTALL RADIATOR ASSEMBLY


    1. A0137Q1

      Install the 2 radiator support cushions and 2 grommets to the radiator assembly.

    2. A01369K

      Install the fan assembly to the radiator assembly, with the claws and tighten the bolt.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  80. INSTALL FRONT CROSS MEMBER SUB-ASSEMBLY


    1. A0138MG

      Install the front cross member sub-assembly with the 6 bolts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  81. CONNECT CONDENSER ASSEMBLY (w/ Air Conditioning System)


    1. A0136TM

      Install the radiator assembly with the 2 bolts.

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

  82. INSTALL RADIATOR HOSE NO.2


    1. A0135SS

      Using pliers, grip the claws of the clip and slide the clip to install the radiator hose No.2 to the radiator assembly.

    2. A0137H9

      Using pliers, grip the claws of the clip and slide the clip to connect the radiator hose No.2 to the water outlet box.

  83. INSTALL RADIATOR HOSE


    1. A0137E8

      Using pliers, grip the claws of the clip and slide the clip to install the radiator hose to the radiator assembly.

    2. A0138LZ

      Using pliers, grip the claws of the clip and slide the clip to connect the radiator hose to the water outlet box.

  84. INSTALL FRONT BUMPER COVER

    A0136YZ

    1. Install the 2 clips.

    2. A01360O

      Engage the 13 claws and install the front bumper cover.

    3. A013716E01

      Tighten the 3 bolts and 5 screws.

    4. Install the 3 clips.

    5. Remove the protective tape.

  85. INSTALL WATER BY-PASS HOSE NO.2


    1. A0135US

      Insert the water by-pass hose No.2 to the thermostat housing.

    2. Install the clip.

  86. INSTALL WATER BY-PASS HOSE


    1. A0136XU

      Insert the water by-pass hose to the radiator assembly.

    2. Install the clip.

  87. INSTALL RADIATOR RESERVE TANK ASSEMBLY


    1. Install the radiator reserve tank with the bolt.

      Torque:
      7.5 N*m  { 77 kgf*cm, 66 in.*lbf }
    2. A01367O

      Insert the 2 water by-pass hoses.

    3. Install the 2 clips.

    4. A0135ZD

      Insert the fuel by-pass hose No.5.

    5. Install the clip.

  88. INSTALL INLET AIR CLEANER NO.2


    1. A0136IS

      Using a "torx" socket wrench, install the inlet air cleaner No.2 with the screw.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }
    2. A01390A

      Connect the mass air flow meter connector.

  89. INSTALL INLET AIR CLEANER


    1. A0137J3

      Install inlet air cleaner.

  90. INSTALL BATTERY CARRIER


    1. A01368RE01

      Install the battery carrier with the 3 bolts.

      Torque:
      For A
      7.4 N*m  { 75 kgf*cm, 65 in.*lbf }
      For B
      17 N*m  { 175 kgf*cm, 13 ft.*lbf }

  91. CONNECT ENGINE WIRE


    1. A0138WG

      Connect the battery terminal B with the nut.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }
    2. A01392G

      Connect the 2 ground terminals with the 2 bolts.

    3. A0136CN

      Connect the glow relay connector.

    4. Push the retainer as shown in the illustration.

    5. A0138GV

      Connect the ECM connectors to the ECM.

    6. Turn the retainers as shown in the illustration.

    7. A0137HGE01

      Install the engine relay block with the bolt.

      Torque:
      For A
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
      For B
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    8. Connect the engine wire harness connectors to the engine room relay block.

  92. INSTALL COWL TOP PANEL OUTER


    1. A0136J7

      Install the cowl top panel outer with the 10 bolts.

      Torque:
      9.2 N*m  { 94 kgf*cm, 81 in.*lbf }

  93. INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY


    1. Connect the connector.

    2. A0136OQ

      Install the front wiper motor and link assembly with the 2 bolts.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }

  94. INSTALL COWL TOP VENTILATOR LOUVER RH


    1. Connect the washer hose.

    2. A0136GYE01

      Engage the 8 claws and install the cowl top ventilator louver RH.

    3. Install the clip.

  95. INSTALL COWL TOP VENTILATOR LOUVER LH


    1. Connect the washer hose.

    2. A0136Y2E01

      Engage the 9 claws and install the cowl top ventilator louver LH.

    3. Install the clip.

  96. INSTALL HOOD TO COWL TOP SEAL

    A01379NE01

    1. Engage the 8 clips and install the hood to cowl top seal.

  97. INSTALL FRONT WIPER ARM LH

    A01390ME03

    1. Scrape any metal powder off the serrated part of the wiper arm with a round file or equivalent (when reinstalling).

    2. Clean the wiper pivot serrations with a wire brush.

    3. Operate the wiper, then stop the windshield wiper motor assembly in the automatic stop position.

    4. Provisionally install the front wiper main arm with the nut.

    5. Install the front wiper secondary arm onto the front wiper motor and link assembly.

    6. A0138WNE04

      Align the blade tip with the mark on the windshield glass, as shown in the illustration.

    7. Tighten the nut of the front wiper main arm.

      Torque:
      21 N*m  { 209 kgf*cm, 15 ft.*lbf }

  98. INSTALL FRONT WIPER ARM HEAD CAP

    A0137M4

    1. Engage the claw and install the front wiper arm head cap.

  99. INSTALL BATTERY


    1. A01382G

      Install the battery and clamp with the bolt.

      Torque:
      15 N*m  { 154 kgf*cm, 11 ft.*lbf }

    2. Connect the positive battery cable.

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

  100. INSTALL ENGINE COVER NO.1


    1. Install the engine cover No.1.

  101. ADD MANUAL TRANSAXLE OIL

  102. INSPECT MANUAL TRANSAXLE OIL


    1. Stop the vehicle in a level place.

    2. Remove the transmission filler plug and the gasket.

    3. A01361GE03

      Check that the oil surface is within 5 mm (0.20 in.) of the lowest point of the transmission filler plug opening.

      Note


      • Excessively large or small amounts of oil may cause problems.


      • After replacing the oil, drive the vehicle and check the oil level again.

    4. When the oil level is low, check for oil leakage.

    5. Install the transmission filler plug and a new gasket.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

  103. ADD ENGINE COOLANT


    1. A01375N

      Install the drain plug with an O-ring and a new clip.

    2. Connect the radiator hose No.2.

    3. Pour engine coolant into the reserve tank assembly.

      Capacity
      4.0 to 4.4 L

      Note

      Do not substitute water for engine coolant.

      Tech Tips


      • Use of improper engine coolant may damage the engine coolant system.

      • Use only Premium Long Life Coolant for 1WZ and 2WZ-TV. Pre-mixed. Green. or similar high quality ethylene glycol based non-silicate, non-amine, non-nitrite, and non-borate engine coolant with long-life hybrid organic acid technology (coolant with long-life hybrid organic acid technology consists of a combination of low phosphates and organic acids).

    4. Check the engine coolant level inside the radiator assembly by pressing the inlet and outlet radiator hoses several times by hand. If the engine coolant level goes down, add engine coolant.

    5. A0136NJ

      Connect the water by-pass hose with the hose clamp.

      Tech Tips

      Connect the water by-pass hose, when the fluid flows clean and without air bubbles.

    6. Slowly pour engine coolant into the radiator reservoir until it reaches the FULL line.

    7. Install the reservoir tank cap sub-assembly securely.

  104. CONNECT BATTERY NEGATIVE TERMINAL


    1. Connect the negative battery cable.

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

  105. INSPECT FOR ENGINE COOLANT LEAKS


    1. Start the engine.

    2. Maintain the engine speed at 1,500 rpm until the first cooling cycle (cooling fan on).

    3. Stop the engine and wait for cool down.

    4. If necessary top up the level to the maximum mark.

  106. INSPECT ENGINE OIL LEAKS


    1. Start the engine. Make sure that no oil leaks from the connection point of the engine oil pressure switch.

  107. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Tech Tips

    Click here

  108. INSTALL ENGINE UNDER COVER


    1. A013649

      Install the engine under cover with the 5 screws.

    2. Install the 9 bolts.