ENGINE ASSEMBLY INSTALLATION

PROCEDURE


  1. REMOVE ENGINE FROM ENGINE STAND


    1. A004NF0E02
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install the No. 1 and No. 2 engine hangers with 2 bolts as shown in the illustration.

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

      Tech Tips

      Part No.
      No. 1 engine hanger 12281-26040
      No. 2 engine hanger 12282-26010
      Bolt 91552-81025 or 90105-W0042

      • Insert the claw of the No. 1 engine hanger into the hole of the cylinder head.

      • Fit the fork part of the No. 2 engine hanger onto the rib of the cylinder head.

    2. Install a sling device and chain block to the engine and hang the engine.

    3. Remove the engine from the engine stand.

  2. INSTALL FLYWHEEL SUB-ASSEMBLY


    1. A004SJ5E02

      Hold the crankshaft pulley with SST.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
    2. A004TIYE02

      Using a T55 "TORX" socket wrench, install 8 new bolts and uniformly tighten the bolts in several steps in the sequence shown in the illustration.

      Torque:
      71 N*m  { 720 kgf*cm, 52 ft.*lbf }

      Note


      • Do not reuse the flywheel installation bolts.

      • Be sure to check the tightening torque within 5 minutes after tightening.

      • Do not impact or damage the flywheel installation bolts. Be sure to handle them carefully.

      • Make sure there is no oil on the bolts.

      Tech Tips

      Make sure that the seating surface of the flywheel installation bolts and installation surfaces of the crankshaft and flywheel are free from oil and foreign matter.

  3. INSTALL CLUTCH DISC ASSEMBLY

    Click here

  4. INSTALL CLUTCH COVER ASSEMBLY

    Click here

  5. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY

    Click here

  6. INSTALL MANUAL TRANSAXLE ASSEMBLY

    Click here

  7. INSTALL STIFFENER PLATE LH


    1. A004NZXE02

      Temporarily install the stiffener plate LH with the 4 bolts.

    2. While holding the stiffener plate LH against the transaxle, tighten bolt A, and then tighten bolts B, C and D.

      Torque:
      46 N*m  { 469 kgf*cm, 34 ft.*lbf }

  8. INSTALL STIFFENER PLATE RH


    1. A004RI9E02

      Temporarily install the stiffener plate RH with the 4 bolts.

    2. While holding the stiffener plate RH against the transaxle, tighten bolt A, and then tighten bolts B, C and D.

      Torque:
      46 N*m  { 469 kgf*cm, 34 ft.*lbf }

  9. INSTALL OIL PAN INSULATOR


    1. Install the oil pan insulator with the 2 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  10. INSTALL ENGINE MOUNTING INSULATOR RH

    Tech Tips

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


    1. Install the engine mounting insulator RH with the 3 bolts.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

  11. INSTALL ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. Install the engine mounting insulator LH with the 4 bolts.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

  12. INSTALL ENGINE MOUNTING BRACKET LH

    Tech Tips

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


    1. Install the engine mounting bracket LH with the 4 bolts.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

  13. INSTALL REAR ENGINE MOUNTING BRACKET


    1. Install the rear engine mounting bracket with the 5 bolts.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

  14. INSTALL FRONT ENGINE MOUNTING BRACKET


    1. Install the front engine mounting bracket with the 3 bolts.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

  15. INSTALL ENGINE WIRE

  16. INSTALL STARTER ASSEMBLY (for VALEO Made)

    Click here

  17. INSTALL STARTER ASSEMBLY (for DENSO Made)

    Click here

  18. INSTALL NO. 1 AIR TUBE


    1. Install the No. 1 air tube with the 2 bolts and tighten the clamp.

      Torque:
      for bolt
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      for clamp
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

      Note

      Before installation, remove any oil residue from the inside of the tube and hose.

  19. INSTALL REAR ENGINE MOUNTING INSULATOR


    1. Install the rear engine mounting insulator with the 3 bolts and 2 nuts.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

  20. INSTALL ENGINE WITH TRANSAXLE


    1. Place the engine on an engine lifter.

      Tech Tips

      Place the engine on wooden blocks or equivalent so that the engine is level.

    2. Using the chain block, slowly install the engine to the vehicle and the intermediate shaft to the pinion.

      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.

      • Align the matchmarks on the intermediate shaft and pinion.

    3. A004QPT

      Temporarily install the suspension crossmember with 2 new bolts.

      Text in Illustration
      A004NPW New Bolt
      A004NAK Bolt

    4. Temporarily install the rear brace RH and LH with 2 new bolts and the 4 bolts.

    5. Connect the engine mounting insulator LH with the bolt and nut.

      Torque:
      56 N*m  { 571 kgf*cm, 41 ft.*lbf }

      Tech Tips

      While holding the bolt in place, tighten the nut.

    6. A004TMOE02

      Connect the engine mounting insulator RH with the 2 bolts and 2 nuts.

      Torque:
      for bolt, nut A
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }
      for nut B
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }
    7. A004T98E02

      Tighten the 8 bolts.

      Torque:
      for bolt A
      137 N*m  { 1397 kgf*cm, 101 ft.*lbf }
      for bolt B
      93 N*m  { 948 kgf*cm, 69 ft.*lbf }

    8. Remove the 2 bolts, No. 1 and No. 2 engine hangers.

    9. Attach the 3 clamps and connect the wire harness.

    10. Connect the cable bracket with the bolt.

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

  21. INSTALL FRONT ENGINE MOUNTING INSULATOR


    1. A004NDIE01
      Text in Illustration
      *1 Through Bolt
      *2 Nut

      Install the front engine mounting insulator with through bolt and nut.

      Torque:
      145 N*m  { 1479 kgf*cm, 107 ft.*lbf }

  22. INSTALL FRONT CROSSMEMBER SUB-ASSEMBLY


    1. A004MX1E02

      Install the front crossmember with the 6 bolts.

      Torque:
      for bolt A
      99 N*m  { 1010 kgf*cm, 73 ft.*lbf }
      for bolt B
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

  23. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH


    1. A004OJNE02

      Install the front suspension member reinforcement LH with the 4 bolts.

      Torque:
      99 N*m  { 1010 kgf*cm, 73 ft.*lbf }

      Note

      Tighten the bolts in the order shown in the illustration.

  24. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  25. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

    Click here

  26. INSTALL FRONT AXLE ASSEMBLY LH

    Click here

  27. INSTALL FRONT AXLE ASSEMBLY RH

    Click here

  28. CONNECT FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  29. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  30. INSTALL FRONT AXLE SHAFT NUT LH

    Click here

  31. INSTALL FRONT AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedure as for the LH side.

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

    Click here

  33. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  34. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  35. CONNECT CLUTCH RELEASE CYLINDER ASSEMBLY


    1. A004R9QE02

      Connect the clutch release cylinder and flexible hose bracket with the 6 bolts.

      Torque:
      for bolt A
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      for bolt B
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  36. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. Connect the transmission control cable to the control cable bracket with 2 new clips.

    2. Install the 2 pins.

  37. CONNECT COMPRESSOR WITH PULLEY ASSEMBLY (w/ Air Conditioning System)


    1. Using an E8 "TORX" socket wrench, connect the compressor with the 2 stud bolts.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    2. A004SGKE02
      Text in Illustration
      *1 Nut

      Install the 2 bolts and 2 nuts.

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

    3. Connect the connector.

  38. INSTALL FAN AND GENERATOR V BELT

    Click here

  39. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Click here

  40. INSTALL INJECTOR DRIVER


    1. Install the injector driver with the 3 screws.

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

    2. Attach the clamp and connect the 4 connectors.

  41. CONNECT NO. 2 RADIATOR HOSE


    1. Connect the No. 2 radiator hose.

  42. CONNECT WATER BY-PASS HOSE


    1. Connect the water by-pass hose.

  43. INSTALL INTERCOOLER AIR HOSE

    Click here

  44. CONNECT NO. 1 RADIATOR HOSE


    1. Connect the No. 1 radiator hose.

  45. CONNECT INLET HEATER WATER HOSE


    1. Connect the inlet heater water hose.

  46. CONNECT OUTLET HEATER WATER HOSE


    1. Connect the outlet heater water hose

  47. CONNECT HOSES AND CONNECTORS


    1. Connect the vacuum pump hose.

    2. Connect the 2 fuel hoses.

    3. A004S5W

      Connect the ECM connector and lower the lever.

      Note


      • When connecting the connector, make sure that dirt, water and other foreign matter is not stuck between the connector and ECM.


      • Make sure that the lever is securely lowered.

    4. Attach the 4 clamps and connect the wire harness.

    5. Install the air cleaner bracket with the 5 bolts.

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

    6. for LHD:

      Attach the 5 clamps and connect the 2 connectors.

    7. for RHD:

      Attach the 3 clamps and connect the 2 connectors.

    8. Connect the ground cable with the bolt.

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

    9. Connect the 3 connectors, attach the 2 claws to install the No. 1 engine room relay block and install the 2 nuts.

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

    10. Connect the current sensor connector.

    11. Install the engine room No. 1 relay block cover.

  48. INSTALL FUEL FILTER ASSEMBLY (w/o Combustion Type Power Heater)

    Click here

  49. INSTALL FUEL FILTER ASSEMBLY (w/ Combustion Type Power Heater)

    Click here

  50. INSTALL AIR CLEANER CASE


    1. Install the air cleaner case with the 3 bolts.

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

  51. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  52. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. Connect the air cleaner hose.

    2. Attach the 4 clamps to install the air cleaner cap.

    3. Connect the No. 2 ventilation hose.

    4. Connect the mass air flow meter connector.

  53. INSTALL NO. 3 AIR HOSE

    Click here

  54. CONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY


    1. Connect the No. 2 vacuum transmitting hose to the intake manifold.

  55. INSTALL BATTERY CARRIER

    Click here

  56. INSTALL BATTERY TRAY

  57. INSTALL BATTERY

  58. INSTALL BATTERY INSULATOR

  59. INSTALL BATTERY CLAMP SUB-ASSEMBLY

    Click here

  60. INSTALL DIFFERENTIAL PRESSURE SENSOR ASSEMBLY

    Click here

  61. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  62. ADD MANUAL TRANSAXLE OIL

    Click here

  63. INSPECT FOR MANUAL TRANSAXLE OIL LEAK

  64. ADD ENGINE OIL

    Click here

  65. CONNECT CABLE TO POSITIVE BATTERY TERMINAL

  66. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  67. ADD ENGINE COOLANT

    Click here

  68. BLEED FUEL SYSTEM

    Click here

  69. PERFORM REGISTRATION


    1. Perform registration of the injector compensation codes.


    2. Perform registration of the pilot quantity learning.


  70. PERFORM INITIALIZATION


    1. Perform initialization of the crank time compensation reset function.


  71. PERFORM THROTTLE VALVE FULLY CLOSED POSITION LEARNING

    Click here

  72. INSPECT FOR OIL LEAK

    Click here

  73. INSPECT FOR COOLANT LEAK

    Click here

  74. INSPECT FOR FUEL LEAK

    Click here

  75. INSPECT FOR EXHAUST GAS LEAK

    Click here

  76. INSTALL REAR ENGINE UNDER COVER RH

    Click here

  77. INSTALL REAR ENGINE UNDER COVER LH


    1. Install the rear engine under cover LH with the 5 clips.

  78. INSTALL NO. 2 ENGINE UNDER COVER

    Click here

  79. INSTALL CENTER NO. 4 ENGINE UNDER COVER


    1. Install the center No. 4 engine under cover with the 2 clips.

  80. INSTALL NO. 1 ENGINE UNDER COVER

    Click here

  81. INSTALL FRONT LOWER BUMPER ABSORBER

    Click here

  82. INSTALL NO. 1 ENGINE COVER

    Click here

  83. INSTALL RADIATOR SUPPORT OPENING COVER

    Click here

  84. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY


    1. Install the outer cowl top panel with the 9 bolts.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

    2. Attach the clamp and connect the connector.

  85. INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY

    Click here

  86. INSTALL FRONT WHEEL

    Click here

  87. CHECK IDLE SPEED

    Click here

  88. CHECK MAXIMUM ENGINE SPEED

    Click here

  89. ADJUST FRONT WHEEL ALIGNMENT

    Click here

  90. CHECK ABS SPEED SENSOR SIGNAL

    Click here

  91. PERFORM CLUTCH ENGAGEMENT POINT LEARNING

    Click here