ENGINE ASSEMBLY(w/ Glow Plug Controller) INSTALLATION

CAUTION / NOTICE / HINT

Note


  • As the engine assembly with transaxle is extremely heavy, the engine lifter may suddenly drop if the instructions listed in the repair manual are not followed. Therefore, always follow the instructions listed in the repair manual when performing this procedure.

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

  • After replacing the engine assembly, perform both "Injector Compensation" and "Pilot Quantity Learning Values Reset" using the GTS.

    Click here

PROCEDURE


  1. INSTALL ENGINE HANGERS

    Click here

  2. REMOVE ENGINE 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.

  3. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    Click here

  4. INSTALL FLYWHEEL SUB-ASSEMBLY

    Click here

  5. INSTALL CRANK POSITION SENSOR

    Click here

  6. INSTALL CYLINDER BLOCK SIDE COVER


    1. Install the cylinder block side cover and plate washer to the cylinder block sub-assembly with the bolt.

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

  7. INSTALL EXHAUST MANIFOLD

    Click here

  8. INSTALL TURBOCHARGER SUB-ASSEMBLY

    Click here

  9. INSTALL MANIFOLD STAY

    Click here

  10. INSTALL TURBOCHARGER STAY

    Click here

  11. INSTALL NO. 1 TURBO WATER PIPE SUB-ASSEMBLY

    Click here

  12. CONNECT NO. 2 TURBO WATER HOSE

    Click here

  13. CONNECT NO. 1 TURBO WATER HOSE

    Click here

  14. INSTALL MANIFOLD SUPPORT BRACKET


    1. Install the manifold support bracket to the cylinder block sub-assembly with the 3 bolts.

      Torque:
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  15. INSTALL NO. 2 EXHAUST MANIFOLD


    1. Install a new outlet turbine elbow gasket to the turbocharger sub-assembly.

    2. Temporarily install the No. 2 exhaust manifold to the turbocharger sub-assembly, No. 1 converter support bracket, manifold stay and No. 2 converter support bracket with the 4 bolts and 3 new nuts.

      B0041OHN01

    3. Fully tighten the 4 bolts and 3 nuts in the order shown in the illustration.

      Torque:
      Nut
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }
      Bolt
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

    4. Engage the clamp to connect the exhaust gas temperature sensor wire to the wiring harness clamp bracket.

    5. Engage the claw to connect the exhaust gas temperature sensor wire connector to the wiring harness clamp bracket.

    6. Install the wiring harness clamp bracket to the timing chain cover sub-assembly with the bolt.

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

    7. Connect the exhaust gas temperature sensor connector.

    8. Connect the camshaft position sensor connector.

  16. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

    Click here

  17. INSTALL NO. 4 MANIFOLD SUPPORT BRACKET

    Click here

  18. INSTALL NO. 5 MANIFOLD SUPPORT BRACKET

    Click here

  19. INSTALL NO. 2 VACUUM PIPE

    Click here

  20. INSTALL NO. 1 TURBO INSULATOR

    Click here

  21. INSTALL SENSOR BRACKET

    Click here

  22. INSTALL WIRING HARNESS CLAMP BRACKET


    1. Install the wiring harness clamp bracket to the cylinder head cover sub-assembly.

  23. INSTALL NO. 2 ENGINE COVER BRACKET

    Click here

  24. INSTALL DIFFERENTIAL PRESSURE SENSOR ASSEMBLY

    Click here

  25. INSTALL WIRING HARNESS CLAMP BRACKET

    Click here

  26. INSTALL NO. 1 WIRING HARNESS HEAT INSULATOR

    Click here

  27. INSTALL NO. 2 AIR TUBE


    1. B0042JAC01
      *a View (A)
      *b LH of Engine
      *c Rear of Engine

      Connect the No. 2 air tube to the diesel throttle body assembly with the hose clamp as shown in the illustration.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

      Note

      One minute after tightening the hose clamp, check that residual torque is 3.2 N*m (33 kgf*cm, 28 in.*lbf) or more.

    2. Install the No. 2 air tube with the 2 bolts.

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

  28. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine.

  29. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)

    Click here

  30. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)

    Click here

  31. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transaxle)

    Click here

  32. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY (for Manual Transaxle)

    Click here

  33. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Manual Transaxle)

    Click here

  34. INSPECT CLUTCH PIPE LINE (for Manual Transaxle)

    Click here

  35. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Manual Transaxle)

    Click here

  36. INSTALL BLEEDER TO ACCUMULATOR TUBE (for Manual Transaxle)

    Click here

  37. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

    Click here

  38. CONNECT WIRE HARNESS (for Manual Transaxle)


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

    Click here

  40. INSTALL STARTER ASSEMBLY (w/ Stop And Start System)

    Click here

  41. INSTALL NO. 1 AIR TUBE

    Click here

  42. INSTALL ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


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

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

  43. 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.


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

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

    2. Connect the cooler pipe clamp to the engine mounting insulator sub-assembly RH.

    3. Install the cooler pipe clamp bracket to the engine mounting insulator sub-assembly with the bolt.

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

    4. Install the radiator reserve tank assembly with the 2 bolts.

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

  44. TEMPORARILY TIGHTEN REAR ENGINE MOUNTING INSULATOR


    1. Temporarily install the rear engine mounting insulator with the through bolt.

  45. TEMPORARILY TIGHTEN FRONT ENGINE MOUNTING INSULATOR


    1. Temporarily install the front engine mounting insulator with the through bolt and nut.

  46. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


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

      Note

      Place the 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 LH and engine mounting insulator sub-assembly RH 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

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

      Tech Tips

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

    4. B0041QJN01

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

      Torque:
      Nut (A)
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }
      Nut (B)
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

    5. Install the front crossmember sub-assembly with the 4 bolts.

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

    6. Connect the front engine mounting insulator to the front crossmember sub-assembly with the 2 bolts.

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

  47. REMOVE ENGINE HANGERS


    1. Remove the 2 bolts, No. 1 engine hanger and No. 2 engine hanger.

  48. CONNECT NO. 1 CLUTCH HOSE (for Manual Transaxle)


    1. Install a new clip to connect the No. 1 clutch hose to the flexible hose bracket.

    2. Using a 10 mm union nut wrench, connect the No. 1 clutch hose to the accumulator to flexible hose tube.

      Torque:
      15.2 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench.

      Click here

  49. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

  50. INSTALL FRONT SUSPENSION MEMBER REAR BRACE LH

    Click here

  51. INSTALL FRONT SUSPENSION MEMBER REAR BRACE RH

    Tech Tips

    Perform the same procedure as for the LH side.

  52. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH

    Click here

  53. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Click here

  54. INSTALL FRONT ENGINE MOUNTING BRACKET LOWER REINFORCEMENT

    Click here

  55. INSTALL REAR ENGINE MOUNTING INSULATOR


    1. Install the rear engine mounting insulator with the through bolt.

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

  56. INSTALL FRONT ENGINE MOUNTING INSULATOR


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

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

      Tech Tips

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

  57. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  58. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

    Click here

  59. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  60. INSTALL FRONT CENTER FLOOR BRACE SUB-ASSEMBLY

    Click here

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

    Click here

  62. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  63. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

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


    1. Using an E8 "TORX" socket wrench, temporarily install the compressor assembly with pulley with the 2 stud bolts.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    2. B00420GN01

      Install the compressor assembly with pulley with the 2 bolts and 2 nuts.

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

      Tech Tips

      Tighten the bolts and nuts in the order shown in the illustration to install the compressor assembly with pulley.

    3. Connect the connector.

  65. INSTALL V-RIBBED BELT

    Click here

  66. INSPECT V-RIBBED BELT

    Click here

  67. CONNECT OUTLET HEATER WATER HOSE


    1. Connect the outlet heater water hose to the water by-pass pipe sub-assembly and slide the clip to secure it.

  68. CONNECT INLET HEATER WATER HOSE A (w/o Combustion Type Power Heater)


    1. Connect the inlet heater water hose A to the inlet heater water pipe A and slide the clip to secure it.

  69. CONNECT INLET HEATER WATER HOSE D (w/ Combustion Type Power Heater)


    1. Connect the inlet heater water hose D to the inlet heater water pipe A and slide the clip to secure it.

  70. CONNECT NO. 1 RADIATOR HOSE


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

  71. CONNECT NO. 2 RADIATOR HOSE


    1. Connect the No. 2 radiator hose to the water inlet and slide the clip to secure it.

  72. CONNECT WATER BY-PASS HOSE


    1. Connect the water by-pass hose to the water inlet and slide the clip to secure it.

  73. CONNECT UNION TO CONNECTOR TUBE HOSE


    1. Connect the union to connector tube hose to the cylinder head cover sub-assembly and slide the clip to secure it.

  74. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)


    1. Install the transmission control cable assembly to the rear engine mounting bracket with the bolt.

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

    2. Install the 2 transmission control cable assemblies to the control cable bracket assembly with 2 new clips.

    3. Install the 2 transmission control cable assemblies to the manual transaxle assembly with the 2 clips.

  75. INSTALL INTERCOOLER AIR HOSE


    1. B0044LRC01
      *a View (A)
      *b View (B)
      *c Top of Engine
      *d Front of Engine

      Install the intercooler air hose with the 2 hose clamps as shown in the illustration.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

      Note

      One minute after tightening the hose clamps, check that the residual torque is 3.2 N*m (33 kgf*cm, 28 in.*lbf) or more.

  76. INSTALL NO. 3 AIR HOSE


    1. B00433RC01
      *a View (A)
      *b View (B)
      *c LH of Engine
      *d Front of Engine
      *e Top of Engine
      *f RH of Engine

      Install the No. 3 air hose with the 2 hose clamps as shown in the illustration.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

      Note

      One minute after tightening the hose clamps, check that the residual torque is 3.2 N*m (33 kgf*cm, 28 in.*lbf) or more.

  77. INSTALL NO. 2 BATTERY CARRIER


    1. Install the No. 2 battery carrier with the 4 bolts.

      Torque:
      18.5 N*m  { 189 kgf*cm, 14 ft.*lbf }

  78. INSTALL AIR CLEANER BRACKET


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

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

  79. INSTALL FUEL FILTER SUPPORT


    1. Install the fuel filter support with the 3 bolts.

      Torque:
      17.5 N*m  { 178 kgf*cm, 13 ft.*lbf }

    2. Connect the wire harness clamp to the fuel filter support.

  80. INSTALL GLOW PLUG RELAY ASSEMBLY


    1. Install the glow plug relay assembly to the fuel filter support with the bolt.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

    2. Connect the wire harness clamp to the fuel filter support.

  81. CONNECT ENGINE WIRE


    1. Connect the No. 3 engine wire to the manual transaxle assembly with the bolt.

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

    2. Engage the 2 wire harness clamps.

    3. Connect the 4 wire harness connectors and wire harness to the engine room relay block and junction block assembly, and engage the 2 claws.

    4. Install the 2 nuts to the engine room relay block and junction block assembly.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

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

    6. Engage the 3 wire harness clamps to the fuel filter support.

    7. Lower the lever to connect the ECM connector.

  82. INSTALL FUEL FILTER ASSEMBLY

    Click here

  83. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. Install the air cleaner case sub-assembly with the 3 bolts.

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

    2. Install the air cleaner filter element sub-assembly.

  84. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. Install the air cleaner cap sub-assembly with the hose clamp.

    2. Lock the 2 lock clamps.

    3. Connect the wire harness clamp, connector and ventilation hose.

  85. INSTALL BATTERY


    1. Install the battery tray.

    2. Set the battery to the battery tray.

    3. Install the battery clamp sub-assembly and battery clamp bolt with the bolt and nut.

      Torque:
      Bolt
      16.5 N*m  { 168 kgf*cm, 12 ft.*lbf }
      Nut
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

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

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

  86. INSTALL OUTER COWL TOP PANEL (for LHD)

    Click here

  87. INSTALL OUTER COWL TOP PANEL (for RHD)

    Click here

  88. 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

  89. ADD MANUAL TRANSAXLE OIL (for Manual Transaxle)

    Click here

  90. ADD ENGINE OIL

    Click here

  91. ADD ENGINE COOLANT

    Click here

  92. BLEED CLUTCH LINE (for Manual Transaxle)

    Click here

  93. BLEED AIR FROM FUEL SYSTEM

    Click here

  94. INSPECT FOR TRANSAXLE OIL LEAK

  95. CHECK ENGINE OIL LEVEL

    Click here

  96. INSPECT FOR COOLANT LEAK

    Click here

  97. INSPECT FOR FUEL LEAK

    Click here

  98. INSPECT FOR EXHAUST GAS LEAK

  99. INSPECT FOR OIL LEAK

    Click here

  100. INSTALL NO. 1 ENGINE COVER (w/ No. 1 Engine Cover)


    1. B0044O9C01
      B0043VS Engage the 2 hooks first
      B0042CO Engage the 2 grommets next

      Engage the 2 hooks to the No. 2 engine cover bracket. Then align the 2 grommets with the 2 pins, and press down on the No. 1 engine cover to attach the pins.

  101. INSTALL REAR ENGINE UNDER COVER LH


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

  102. INSTALL REAR ENGINE UNDER COVER RH


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

  103. INSTALL FRONT NO. 3 ENGINE UNDER COVER (for Full Cover Type)


    1. Install the front No. 3 engine under cover with the 4 clips.

  104. INSTALL CENTER NO. 4 ENGINE UNDER COVER (for Half Cover Type)


    1. Install the center No. 4 engine under cover with the 5 clips.

  105. INSTALL CENTER NO. 4 ENGINE UNDER COVER (for Full Cover Type)


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

  106. INSTALL NO. 1 ENGINE UNDER COVER (for Half Cover Type)


    1. Install the No. 1 engine under cover with the 2 bolts and 7 clips.

  107. INSTALL NO. 1 ENGINE UNDER COVER (for Full Cover Type)


    1. Install the No. 1 engine under cover with the 2 bolts and 11 clips.

  108. INSTALL FRONT LOWER BUMPER ABSORBER


    1. Install the front lower bumper absorber with the 8 bolts and 4 screws.

  109. INSTALL FRONT WHEELS

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

  110. ADJUST FRONT WHEEL ALIGNMENT

    Click here

  111. CHECK ABS SPEED SENSOR SIGNAL

    Click here