ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

Note

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

PROCEDURE


  1. INSTALL ENGINE HANGER

    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 ENGINE WIRE


    1. Connect all the clamps and connectors, and install the engine wire to the engine assembly.

    2. B0043SEC01
      *1 Nut
      *2 Wire Harness Bracket

      Install the 3 bolts and nut to the cylinder head sub-assembly.

      Torque:
      Bolt A and Nut
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Bolt B
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

    3. Install the wire harness bracket to the cylinder head cover sub-assembly with the bolt.

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

    4. Install the 2 nuts to the cylinder head cover sub-assembly.

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

  4. INSTALL FLYWHEEL SUB-ASSEMBLY

    Click here

  5. INSTALL CLUTCH DISC ASSEMBLY

    Click here

  6. INSTALL CLUTCH COVER ASSEMBLY

    Click here

  7. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY

    Click here

  8. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY

    Click here

  9. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  10. INSPECT CLUTCH PIPE LINE

    Click here

  11. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY

    Click here

  12. INSTALL BLEEDER CLUTCH RELEASE TUBE

    Click here

  13. INSTALL MANUAL TRANSAXLE ASSEMBLY

    Click here

  14. CONNECT WIRE HARNESS

    Click here

  15. INSTALL STARTER ASSEMBLY

    Click here

  16. INSTALL GENERATOR ASSEMBLY (for 80 A Type)

    Click here

  17. INSTALL GENERATOR ASSEMBLY (for 100 A Type)

    Click here

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

    Click here

  19. INSTALL FLYWHEEL HOUSING SIDE COVER

    Click here

  20. 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 }

  21. INSTALL ENGINE MOUNTING INSULATOR RH

    Tech Tips

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


    1. Install the engine mounting insulator 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 RH.

    3. Install the cooler pipe clamp bracket to the engine mounting insulator RH with the bolt.

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

    4. Connect the radiator reservoir tank with the 2 bolts.

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

  22. TEMPORARILY TIGHTEN REAR ENGINE MOUNTING INSULATOR


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

  23. TEMPORARILY TIGHTEN FRONT ENGINE MOUNTING INSULATOR


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

  24. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


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

      Note

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

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

    3. Operate the engine lifter and lift the engine assembly with transaxle to 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 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.

    4. 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.

    5. Install the engine mounting insulator RH with the bolt and 2 nuts.

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

    6. Install the front cross member sub-assembly with the 4 bolts.

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

    7. Connect the front engine mounting insulator to the front cross member sub-assembly with the 2 bolts.

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

  25. CONNECT NO. 1 CLUTCH HOSE


    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 bleeder clutch release 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

  26. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

  27. INSTALL FRONT SUSPENSION MEMBER REAR BRACE LH

    Click here

  28. INSTALL FRONT SUSPENSION MEMBER REAR BRACE RH

    Tech Tips

    Perform the same procedure as for the LH side.

  29. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH

    Click here

  30. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Click here

  31. INSTALL FRONT ENGINE MOUNTING BRACKET LOWER REINFORCEMENT (w/ Reinforcement)

    Click here

  32. FULLY TIGHTEN REAR ENGINE MOUNTING INSULATOR


    1. Tighten the rear engine mounting insulator to the engine mounting bracket with the through bolt.

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

  33. FULLY TIGHTEN FRONT ENGINE MOUNTING INSULATOR


    1. Tighten the front engine mounting insulator with the 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.

  34. INSTALL FRONT DRIVE SHAFT ASSEMBLY

    Click here

  35. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

    Click here

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

    Click here

  37. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  38. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  39. CONNECT WIRE HARNESS


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

    3. Connect the 3 wire harness connectors and wire harness to the engine room junction block 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. Connect the wire harness clamp.

    7. Connect the ECM connector and lower the lever.

  40. INSTALL V-RIBBED BELT

    Click here

  41. CONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

  42. CONNECT SUCTION HOSE SUB-ASSEMBLY (w/ Air Conditioning System)

    Click here

  43. CONNECT DISCHARGE HOSE SUB-ASSEMBLY (w/ Air Conditioning System)

    Click here

  44. CONNECT HEATER WATER INLET HOSE A


    1. Connect the heater water inlet hose A to the cylinder head sub-assembly and slide the clip to secure it.

    2. Connect the hose clamp.

  45. CONNECT HEATER WATER OUTLET HOSE A


    1. Connect the heater water outlet hose A to the No. 1 water by-pass pipe and slide the clip to secure it.

    2. Connect the 2 hose clamps.

  46. CONNECT UNION TO CONNECTOR TUBE HOSE (for LHD)


    1. Connect the union to connector tube hose to the intake manifold and slide the clip to secure it.

  47. CONNECT CHECK VALVE TO BRAKE BOOSTER HOSE (for RHD)


    1. Connect the check valve to brake booster hose to the intake manifold and slide the clip to secure it.

  48. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY


    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. B004528N07

      Install the 2 transmission control cable assemblies to the control cable bracket with 2 new clips (A).

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

    4. Connect the clip and clamp, and install the wire harness with the nut.

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

  49. CONNECT NO. 2 RADIATOR HOSE


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

  50. CONNECT NO. 1 RADIATOR HOSE


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

    2. Install the radiator pipe to the battery carrier with the 2 bolts.

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

  51. INSTALL BATTERY


    1. Install the battery tray to the battery carrier.

    2. Install the battery to the battery tray.

    3. Install the battery clamp sub-assembly 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 positive (+) cable to the positive (+) battery terminal with the nut.

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

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

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

  53. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  54. INSTALL PURGE VALVE (PURGE VSV)

    Click here

  55. 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

  56. FILL BRAKE FLUID RESERVOIR

    Click here

  57. BLEED CLUTCH LINE

    Click here

  58. INSPECT BRAKE FLUID LEVEL IN RESERVOIR

    Click here

  59. INSPECT FOR FLUID LEAK

    Tech Tips

    Check for leaks in the clutch system.

  60. ADJUST TRANSMISSION CONTROL CABLE ASSEMBLY

    Click here

  61. ADD MANUAL TRANSAXLE OIL

    Click here

  62. ADD ENGINE COOLANT

    Click here

  63. ADD ENGINE OIL

    Click here

  64. INSPECT MANUAL TRANSAXLE OIL

    Click here

  65. CHECK ENGINE OIL LEVEL

    Click here

  66. INSPECT FOR FUEL LEAK

    Click here

  67. INSPECT FOR COOLANT LEAK

    Click here

  68. INSPECT FOR OIL LEAK

  69. INSPECT FOR EXHAUST GAS LEAK

  70. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT (w/ Air Conditioning System)

    for HFC-134a (R134a): Click here

    for HFO-1234yf (R1234yf): Click here

  71. WARM UP ENGINE (w/ Air Conditioning System)

    Click here

  72. INSPECT FOR REFRIGERANT LEAK (w/ Air Conditioning System)

    Click here

  73. INSTALL REAR ENGINE UNDER COVER LH


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

  74. INSTALL REAR ENGINE UNDER COVER RH


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

  75. INSTALL CENTER NO. 4 ENGINE UNDER COVER


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

  76. 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.

  77. INSTALL NO. 1 ENGINE UNDER COVER (for Metal Type)


    1. Install the No. 1 engine under cover with the 5 bolts and 2 clips.

  78. INSTALL FRONT LOWER BUMPER ABSORBER


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

  79. INSTALL FRONT WHEELS

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

  80. INSPECT IGNITION TIMING

    Click here

  81. INSPECT ENGINE IDLE SPEED

    Click here

  82. INSPECT CO/HC

    Click here

  83. ADJUST FRONT WHEEL ALIGNMENT

    Click here

  84. INSTALL NO. 1 ENGINE COVER


    1. Engage the 2 front clips, then the rear clip to install the No. 1 engine cover.

      Note


      • Be sure to engage the clips securely.

      • Do not apply excessive force or tap the No. 1 engine cover to engage the clips. This may cause the No. 1 engine cover to break.

  85. CHECK FOR SPEED SENSOR SIGNAL