ДВИГАТЕЛЬ В СБОРЕ УСТАНОВКА

CAUTION / NOTICE / HINT

CAUTION:

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.

PROCEDURE


  1. 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 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 }

  3. INSTALL REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. A01KBWSN01

      Install the rear engine mounting insulator with the 2 bolts and 2 nuts in the order shown in the illustration.

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

  4. INSTALL ENGINE HANGER

    Click here

  5. REMOVE ENGINE FROM ENGINE STAND

    Note


    • Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

    • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.


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

    2. Remove the engine from the engine stand.

  6. FIX ENGINE ASSEMBLY

    Click here

  7. INSTALL FLYWHEEL WITH DAMPER ASSEMBLY


    1. A01KB34N01

      Using SST, hold the crankshaft pulley.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
    2. A01KCEIN01

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

      Torque:
      71 N*m  { 724 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 with damper assembly are free from oil and foreign matter.

  8. INSTALL CLUTCH DISC ASSEMBLY

    Click here

  9. INSTALL CLUTCH COVER ASSEMBLY

    Click here

  10. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY

    Click here

  11. INSTALL MANUAL TRANSAXLE ASSEMBLY

    Click here

  12. INSTALL STIFFENER PLATE LH


    1. A01KBQEN01

      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 }

  13. INSTALL STIFFENER PLATE RH


    1. A01KB7JN01

      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 }

  14. 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 }

  15. INSTALL ENGINE MOUNTING BRACKET LH

    Tech Tips

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


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

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

  16. INSTALL REAR ENGINE MOUNTING BRACKET


    1. Temporarily install the rear engine mounting bracket with the 5 bolts.

    2. A01KDL9N01

      Tighten the 5 bolts of the rear engine mounting bracket in the order shown in the illustration.

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

  17. INSTALL FRONT ENGINE MOUNTING BRACKET


    1. A01KAJZN01

      Temporarily install the front engine mounting bracket with the 3 bolts.

    2. Tighten the 3 bolts of the front engine mounting bracket in the order shown in the illustration.

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

  18. INSTALL ENGINE WIRE

    Click here

  19. INSTALL STARTER ASSEMBLY

    Click here

  20. INSTALL NO. 1 AIR TUBE


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

      Torque:
      for bolt
      24 N*m  { 245 kgf*cm, 18 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 No. 1 air tube and air hose.

  21. INSTALL ENGINE WITH TRANSAXLE


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

      Tech Tips

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

    2. Temporarily install the front suspension member with the through bolt.

    3. 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


      • 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.

    4. Temporarily install the front suspension member rear brace RH and front suspension member rear brace LH with the 6 bolts.

    5. Temporarily install the 2 bolts to the front suspension member sub-assembly.

    6. 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.

    7. A01KASON01

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

      Torque:
      for bolt and nut A
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }
      for nut B
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }
    8. A01KAOKE01

      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 }
    9. A01KDDKN01

      Install the front crossmember sub-assembly 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 }

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

    11. Install the front suspension member sub-assembly with the through bolt.

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

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

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

      Note

      While holding the nut in place, tighten the through bolt.

  22. INSTALL FUEL HOSE PROTECTOR


    1. Install the fuel hose protector to the cylinder head sub-assembly.

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

  23. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH


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

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

  24. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Click here

  25. INSTALL FRONT LOWER ENGINE MOUNTING BRACKET REINFORCEMENT


    1. Install the front lower engine mounting bracket reinforcement with the 2 bolts.

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

  26. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  27. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

    Click here

  28. INSTALL FRONT AXLE ASSEMBLY LH

    Click here

  29. INSTALL FRONT AXLE ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  30. CONNECT FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  31. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  32. INSTALL FRONT AXLE SHAFT NUT LH

    Click here

  33. INSTALL FRONT AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedure as for the LH side.

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

    Click here

  35. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  36. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  37. CONNECT CLUTCH RELEASE CYLINDER ASSEMBLY


    1. A01KCMMN01

      Connect the clutch release cylinder assembly and clutch flexible hose bracket with the 4 bolts.

      Torque:
      for bolt A
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      for bolt B
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  38. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


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

    2. Install the 2 pins.

  39. CONNECT SUCTION HOSE SUB-ASSEMBLY


    1. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the hose joint.

      Compressor Oil
      ND-OIL 8 or equivalent

    2. Install the O-ring to the suction hose sub-assembly.

    3. Connect the suction hose sub-assembly to the cooler compressor assembly and install the bolt.

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

    4. Connect the connector to the cooler compressor assembly.

  40. CONNECT DISCHARGE HOSE SUB-ASSEMBLY


    1. Sufficiently apply compressor oil to a new O-ring and the fitting surface of the hose joint.

      Compressor Oil
      ND-OIL 8 or equivalent

    2. Install the O-ring to the discharge hose sub-assembly.

    3. Connect the discharge hose sub-assembly to the cooler compressor assembly and install the bolt.

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

  41. INSTALL RADIATOR RESERVOIR ASSEMBLY


    1. Install the radiator reservoir assembly with the 2 bolts.

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

    2. Connect the water by-pass hose to the radiator reservoir assembly, and slide the clamp to secure the hose.

  42. CONNECT NO. 2 WATER BY-PASS HOSE


    1. Connect the No. 2 water by-pass hose to the No. 4 water by-pass pipe, and slide the clamp to secure the hose.

  43. CONNECT NO. 2 RADIATOR HOSE


    1. Connect the No. 2 radiator hose to the water inlet housing, and slide the clamp to secure the hose.

  44. INSTALL INTERCOOLER AIR HOSE

    Click here

  45. CONNECT RADIATOR HOSE SUB-ASSEMBLY


    1. Connect the radiator hose sub-assembly to the cylinder head sub-assembly and slide the clamp to secure the hose.

  46. CONNECT OUTLET HEATER WATER HOSE


    1. Connect the outlet heater water hose to the No. 3 water by-pass pipe and slide the clamp to secure the hose.

  47. CONNECT INLET HEATER WATER HOSE


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

  48. CONNECT HOSES AND CONNECTORS


    1. Connect the vacuum pump hose to the vacuum pump assembly and slide the clip to secure the hose.

    2. Install the injector driver assembly with the 2 nuts.

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

    3. Connect the 4 injector driver connectors and attach the 2 wire harness clamps.

    4. Attach the 3 wire harness clamps to the 3 wire harness clamp brackets.

    5. Install the bolt to the manual transaxle assembly.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

    6. Connect the 2 connectors and attach the wire harness clamp.

    7. Install the ground cable with the bolt and attach the wire harness clamp.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

    8. Install the bolt to the wire harness clamp bracket.

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

    9. Connect the starter wire with the nut.

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

    10. Install the bolt and attach the engine wire cover clamp and engine wire harness clamp.

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

    11. Connect the 2 connectors to the No. 8 engine wire.

    12. Attach the 2 claws and connect the engine wire to the engine room No. 1 relay block with the nut.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

    13. Connect the 3 connectors to the engine room No. 1 relay block.

    14. Install the engine room relay block and junction block cover.

  49. INSTALL ECM

    Click here

  50. INSTALL AIR CLEANER BRACKET


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

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

    2. Connect the 2 fuel hoses to the air cleaner bracket.

    3. Attach the 3 wire harness clamps.

    4. Connect the glow relay and level warning switch connector.

  51. INSTALL FUEL FILTER ASSEMBLY


    1. Install the fuel filter assembly to the air cleaner bracket with the bolt.

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

    2. Connect the 2 fuel hoses to the fuel filter assembly and slide the clamp to secure the hoses.

  52. INSTALL AIR CLEANER SUPPORT


    1. Install the air cleaner support with the 2 nuts.

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

  53. INSTALL AIR CLEANER CASE


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

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

  54. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  55. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. Install the air cleaner cap sub-assembly and attach the 3 clips.

    2. Connect the mass air flow meter connector and wire harness clamp.

    3. Connect the air cleaner hose and tighten the hose clamp.

    4. Connect the PCV hose.

  56. INSTALL NO. 3 AIR HOSE

    Click here

  57. CONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY

    Click here

  58. INSTALL BATTERY BRACKET REINFORCEMENT


    1. Install the battery bracket reinforcement with the 2 bolts.

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

  59. INSTALL FRONT BATTERY BRACKET


    1. Install the front battery bracket with the 4 bolts.

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

    2. Attach the 2 wire harness clamps.

  60. INSTALL BATTERY TRAY

  61. INSTALL BATTERY

  62. INSTALL BATTERY INSULATOR

  63. INSTALL BATTERY CLAMP SUB-ASSEMBLY


    1. Attach the hook of the battery clamp sub-assembly to the front battery bracket.

    2. Partially tighten the nut and temporarily install the bolt.

    3. Attach the 2 wire harness clamps.

    4. Adjust the battery clamp position.

    5. Tighten the nut and bolt.

      Torque:
      for bolt
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }
      for nut
      4.9 N*m  { 50 kgf*cm, 43 in.*lbf }

  64. INSTALL DIFFERENTIAL PRESSURE SENSOR ASSEMBLY

    Click here

  65. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  66. ADD MANUAL TRANSAXLE OIL

    Click here

  67. ADD ENGINE OIL

    Click here

  68. CONNECT CABLE TO POSITIVE BATTERY TERMINAL

  69. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  70. ADD ENGINE COOLANT

    Click here

  71. BLEED AIR FROM FUEL SYSTEM

    Click here

  72. CHARGE REFRIGERANT

    Click here

  73. WARM UP ENGINE

    Click here

  74. INSPECT FOR REFRIGERANT LEAK

    Click here

  75. PERFORM REGISTRATION


    1. Perform registration of the injector compensation codes.

      Click here

    2. Perform registration of the pilot quantity learning.

      Click here

  76. PERFORM INITIALIZATION


    1. Perform initialization of the crank time compensation reset function (See page ).

      Click here

  77. PERFORM THROTTLE VALVE FULLY CLOSED POSITION LEARNING

    Click here

  78. INSPECT FOR OIL LEAK

    Click here

  79. INSPECT FOR COOLANT LEAK

    Click here

  80. INSPECT FOR FUEL LEAK

    Click here

  81. INSPECT FOR EXHAUST GAS LEAK

    Click here

  82. INSPECT FOR MANUAL TRANSAXLE OIL LEAK

  83. INSTALL REAR ENGINE UNDER COVER RH

    Click here

  84. INSTALL REAR ENGINE UNDER COVER LH


    1. Install the rear engine under cover LH with the 2 clips.

  85. INSTALL FRONT FLOOR COVER RH


    1. Install the front floor cover RH with the 3 nuts and 3 clips.

  86. INSTALL FRONT FLOOR COVER

    Click here

  87. INSTALL NO. 1 ENGINE UNDER COVER


    1. Install the No. 1 engine under cover with the 11 clips.

    2. Install the 4 bolts and 2 screws.

  88. INSTALL NO. 1 ENGINE COVER


    1. Attach the 4 clips to install the No. 1 engine cover.

  89. CHECK IDLE SPEED

    Click here

  90. CHECK MAXIMUM ENGINE SPEED

    Click here

  91. ADJUST FRONT WHEEL ALIGNMENT

    Click here

  92. CHECK ABS SPEED SENSOR SIGNAL

    Click here