ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

Note

for Manual Transaxle:

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 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 DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for CVT)


    1. Gently place the engine assembly on wooden blocks or equivalent.

      CAUTION:

      This step should be done while hanging the engine assembly using the engine hangers and a chain block.

    2. Install the drive plate and ring gear sub-assembly.

      Click here

  4. INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY (for CVT)

    Click here

  5. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)

    Click here

  6. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)

    Click here

  7. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)

    Click here

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

    Click here

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

    Click here

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

    Click here

  11. INSPECT CLUTCH PIPE LINE (for Manual Transaxle)

    Click here

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

    Click here

  13. INSTALL BLEEDER CLUTCH RELEASE TUBE (for Manual Transaxle)

    Click here

  14. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

    Click here

  15. INSTALL STARTER ASSEMBLY

    Click here

  16. INSTALL FLYWHEEL HOUSING SIDE COVER

    A01M0BGC04
    *a Protruding Portion
    *b Claw

    1. Insert the protruding portion into the end of the cylinder block sub-assembly and while pushing it along the cylinder block sub-assembly, fit the claw into the stiffening crankcase assembly.

      Note


      • Make sure that the claw makes a click sound, indicating that it fits tightly.

      • Replace the flywheel housing side cover with a new one if the claw does not fit tightly or is deformed.

  17. INSTALL ENGINE WIRE


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

  18. CONNECT NO. 5 WATER BY-PASS HOSE (for CVT)


    1. Connect the No. 5 water by-pass hose to the No. 1 water by-pass pipe.

  19. REMOVE ENGINE HANGER


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

  20. INSTALL WIRE HARNESS CLAMP BRACKET


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

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

    2. Connect the clamp and wire harness to the wire harness clamp bracket.

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

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

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

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

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

  22. 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 }

  23. TEMPORARILY TIGHTEN REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


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

  24. TEMPORARILY TIGHTEN FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

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


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

  25. 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:
      56 N*m  { 571 kgf*cm, 41 ft.*lbf }

      Tech Tips

      Tighten the through bolt while holding the nut.

    4. A01M0HYN08

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

      Torque:
      Nut A
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }
      Nut B
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }
      Bolt
      95 N*m  { 969 kgf*cm, 70 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 sub-assembly to the front crossmember sub-assembly with the 2 bolts.

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

  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

    Click here

  32. FULLY INSTALL REAR ENGINE MOUNTING INSULATOR


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

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

  33. FULLY INSTALL FRONT ENGINE MOUNTING INSULATOR


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

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

      Tech Tips

      Tighten the through bolt while holding the nut.

  34. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT (for CVT)

    Click here

  35. INSTALL FLYWHEEL HOUSING UNDER COVER


    1. Install the flywheel housing under cover.

  36. INSTALL DRIVE SHAFT ASSEMBLY

    Click here

  37. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

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

    Click here

  39. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  40. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  41. CONNECT WIRE HARNESS


    1. for CVT:


      1. Install the No. 3 engine wire to the CVT with the bolt and clamp.

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

    2. for Manual Transaxle:


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

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

    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 engine room 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.

  42. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY

    Click here

  43. CONNECT SUCTION HOSE SUB-ASSEMBLY

    Click here

  44. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

    Click here

  45. INSTALL GENERATOR ASSEMBLY (for 90A Type)

    Click here

  46. INSTALL GENERATOR ASSEMBLY (for 100A Type)

    Click here

  47. INSTALL V-RIBBED BELT

    Click here

  48. ADJUST V-RIBBED BELT

    Click here

  49. INSPECT V-RIBBED BELT

    Click here

  50. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. Connect the fuel tube connector and fuel pipe.

      Note

      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.

  51. 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.

  52. CONNECT OUTLET HEATER WATER HOSE (for Manual Transaxle)


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

  53. CONNECT OUTLET HEATER WATER HOSE (for CVT)


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

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

  54. CONNECT UNION TO VACUUM TUBE HOSE


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

  55. 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.

  56. CONNECT CLUTCH HOSE (for Manual Transaxle)


    1. Connect the clutch hose and install a new clip to the clutch hose.

      Note

      Install the clip as far as it will go.

    2. Using a 10 mm union nut wrench, connect the bleeder clutch release tube to the clutch hose while holding the clutch hose.

      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

      • This torque value is effective when the union nut wrench is parallel to the torque wrench.

      • Do not kink or damage the clutch hose.

      • Do not allow any foreign matter such as dirt or dust to enter the clutch hose from the clip or bracket.

  57. BLEED CLUTCH LINE (for Manual Transaxle)

    Click here

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


    1. Connect 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. A01M02CN06

      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).

  59. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for CVT)


    1. Connect the transmission control cable assembly to the rear engine mounting insulator with the bolt.

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

    2. Install the transmission control cable assembly to the transmission control cable bracket with a new clip.

    3. A01LZ1GC05
      *a P Position
      *b N Position

      Turn the lever clockwise until it stops, then turn it counterclockwise 2 notches.

    4. Install the transmission control cable assembly to the control shaft lever with the nut.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  60. CONNECT NO. 2 RADIATOR HOSE


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

  61. CONNECT NO. 1 RADIATOR HOSE (for Manual Transaxle)


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

  62. CONNECT NO. 1 RADIATOR HOSE (for CVT)


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

    2. Connect breather plug hose to the clamp.

  63. INSTALL BATTERY CARRIER ASSEMBLY


    1. Install the battery carrier assembly with the 4 bolts.

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

    2. Connect the radiator pipe with the 2 bolts.

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

    3. Connect the 2 wire harness clamps.

  64. INSTALL BATTERY


    1. Install the battery tray.

    2. Install the battery.

    3. A01M326C01
      *a Bolt
      *b Nut

      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 cable to the positive (+) battery terminal.

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

  65. 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 wire harness clamp to the air cleaner case.

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

  66. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  67. 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

  68. ADD ENGINE OIL

    Click here

  69. ADD MANUAL TRANSAXLE OIL (for Manual Transaxle)

    Click here

  70. ADD ENGINE COOLANT

    Click here

  71. ADD CONTINUOUSLY VARIABLE TRANSAXLE FLUID (for CVT)

    Click here.

  72. INSPECT ENGINE OIL LEVEL

    Click here

  73. ADJUST SHIFT LEVER POSITION (for Manual Transaxle)

    Click here

  74. INSPECT SHIFT LEVER POSITION (for CVT)

    Click here

  75. ADJUST SHIFT LEVER POSITION (for CVT)

    Click here

  76. INSPECT FOR FUEL LEAK

    Click here

  77. INSPECT FOR COOLANT LEAK

    Click here

  78. INSPECT FOR OIL LEAK

  79. INSPECT FOR EXHAUST GAS LEAK

  80. INSTALL REAR ENGINE UNDER COVER LH


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

  81. INSTALL REAR ENGINE UNDER COVER RH


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

  82. INSTALL NO. 2 ENGINE UNDER COVER


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

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


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

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


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

  85. INSTALL FRONT LOWER BUMPER ABSORBER


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

  86. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  87. WARM UP ENGINE

    Click here

  88. INSPECT FOR REFRIGERANT LEAK

    Click here

  89. INSTALL FRONT WHEELS

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

  90. INSPECT IGNITION TIMING

    Click here

  91. INSPECT ENGINE IDLE SPEED

    Click here

  92. INSPECT CO/HC

    Click here

  93. ADJUST FRONT WHEEL ALIGNMENT

    Click here

  94. INSTALL NO. 2 CYLINDER HEAD COVER


    1. Engage the 4 clips to install the No. 2 cylinder head cover.

      Note


      • Be sure to engage the clips securely.

      • Do not apply excessive force or hit the No. 2 cylinder head cover to engage the clips. This may cause the No. 2 cylinder head cover to break.

  95. INSPECT FOR SPEED SENSOR SIGNAL

    Click here.