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ДВИГАТЕЛЬ В СБОРЕ УСТАНОВКА

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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.

Note:

for Manual Transaxle:

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.

Tip:

Perform "Inspection After Repairs" after replacing the engine assembly, cylinder head sub-assembly, camshaft housing sub-assembly, camshaft timing gear assembly, camshaft timing exhaust gear assembly, piston sub-assembly or piston ring.

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PROCEDURE


  1. Click here

    INSTALL ENGINE MOUNTING INSULATOR LH

    Tip:

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


    1. A01V8XEN01

      Temporarily install the engine mounting insulator LH with the 4 bolts.

    2. Tighten the 4 bolts in the sequence shown in the illustration.

      95 N*m 969 kgf*cm 70 ft.*lbf

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

      7.7 N*m 79 kgf*cm 68 in.*lbf
  2. Click here

    INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    Tip:

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


    1. A01V7BXN01

      Temporarily install the engine mounting insulator sub-assembly RH with the 3 bolts.

    2. Tighten the 3 bolts in the sequence shown in the illustration.

      95 N*m 969 kgf*cm 70 ft.*lbf

    3. Install the radiator reservoir bracket with the bolt.

      5.0 N*m 51 kgf*cm 44 in.*lbf
  3. Click here

    INSTALL REAR ENGINE MOUNTING INSULATOR

    Tip:

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


    1. A01V71FC02
      *A for Manual Transaxle
      *B for CVT

      Temporarily install the rear engine mounting insulator with the 2 bolts and 2 nuts.

    2. Tighten the 2 bolts and 2 nuts in the sequence shown in the illustration.

      95 N*m 969 kgf*cm 70 ft.*lbf
  4. Click here

    INSTALL DRIVE SHAFT BEARING BRACKET


    1. Install the drive shaft bearing bracket with the 3 bolts.

      64 N*m 653 kgf*cm 47 ft.*lbf
  5. Click here

    INSTALL ENGINE HANGER

    Click here

  6. Click here

    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. Attach a sling device and hang the engine with a chain block.

    2. Lift the engine and remove it from the engine stand.

  7. Click here

    FIX ENGINE ASSEMBLY

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  8. Click here

    INSTALL ENGINE WIRE


    1. Install the engine wire to the engine.

  9. Click here

    INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)

    Click here

  10. Click here

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

    Click here

  11. Click here

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

    Click here

  12. Click here

    INSPECT CLUTCH PIPE LINE (for Manual Transaxle)

    Click here

  13. Click here

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

    Click here

  14. Click here

    INSTALL CLUTCH TUBE (for Manual Transaxle)

    Click here

  15. Click here

    INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)

    Click here

  16. Click here

    INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)

    Click here

  17. Click here

    INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transaxle)

    Click here

  18. Click here

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

    Click here

  19. Click here

    INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

    Click here

  20. Click here

    INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY (for CVT)

    Click here

  21. Click here

    INSTALL TRANSFER ASSEMBLY

    Click here

  22. Click here

    INSTALL FLYWHEEL HOUSING SIDE COVER

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  23. Click here

    INSTALL STARTER ASSEMBLY

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  24. Click here

    INSTALL TRANSMISSION OIL COOLER BRACKET (for CVT)

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  25. Click here

    INSTALL OIL COOLER (for CVT)

    Click here

  26. Click here

    CONNECT NO. 2 TRANSMISSION OIL COOLER HOSE (for CVT)

    Click here

  27. Click here

    CONNECT NO. 1 TRANSMISSION OIL COOLER HOSE (for CVT)

    Click here

  28. Click here

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


    1. Install the No. 5 water by-pass hose to the No. 3 water by-pass pipe and oil cooler, and slide the 2 clips to secure the hose.

    2. Attach the 2 clamps.

  29. Click here

    INSTALL STEERING GEAR HEAT INSULATOR (for RHD)

    Click here

  30. Click here

    INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


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

    2. A01V8KPC01
      *1 Alignment Mark
      *2 Protrusion

      Temporarily install the front suspension crossmember with the through bolt.

      Tip:

      When installing the suspension crossmember, align the protrusion of the engine mounting bracket with the alignment mark of the engine mounting insulator.

    3. Place the engine on an engine lifter.

      Tip:

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

    4. Operate the engine lifter and install the engine to the vehicle.

      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.

    5. Temporarily install the front suspension crossmember sub-assembly with 2 bolts.

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

    7. Install the engine mounting insulator LH with the through bolt and nut.

      56 N*m 571 kgf*cm 41 ft.*lbf
      Note:

      While holding the bolt in place, tighten the nut.

    8. A01V6WSN01

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

      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

    9. Tighten the 2 front suspension crossmember bolts.

      137 N*m 1397 kgf*cm 101 ft.*lbf
    10. A01V73EN01

      Tighten the 6 front suspension member rear brace bolts.

      for bolt A
      137 N*m 1397 kgf*cm 101 ft.*lbf
      for bolt B
      93 N*m 948 kgf*cm 69 ft.*lbf

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

    12. Install the air fuel ratio sensor bracket with the bolt. Then connect the air fuel ratio sensor connector.

      39 N*m 398 kgf*cm 29 ft.*lbf

    13. Attach the fuel tube clamp.

    14. A01V8L8N01

      Install the front crossmember sub-assembly with the 6 bolts.

      for bolt A
      99 N*m 1010 kgf*cm 73 ft.*lbf
      for bolt B
      95 N*m 969 kgf*cm 70 ft.*lbf

    15. Tighten the rear engine mounting insulator bolt.

      95 N*m 969 kgf*cm 70 ft.*lbf
      Tip:

      Check that the protrusion of the engine mounting bracket is aligned with the alignment mark of the engine mounting insulator.

    16. Tighten the front engine mounting insulator bolt and nut.

      145 N*m 1479 kgf*cm 107 ft.*lbf
      Note:

      While holding the bolt in place, tighten the nut.

  31. Click here

    INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH


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

      99 N*m 1010 kgf*cm 73 ft.*lbf
  32. Click here

    INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH


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

      99 N*m 1010 kgf*cm 73 ft.*lbf
  33. Click here

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

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  34. Click here

    INSTALL FLYWHEEL HOUSING UNDER COVER

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  35. Click here

    TEMPORARILY INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

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  36. Click here

    TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

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  37. Click here

    CONNECT HEATED OXYGEN SENSOR (for Bank 1 Sensor 2)

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  38. Click here

    INSTALL FRONT EXHAUST PIPE ASSEMBLY

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  39. Click here

    INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH

  40. Click here

    INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

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  41. Click here

    INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

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  42. Click here

    CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

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  43. Click here

    CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

    Tip:

    Use the same procedure described for the LH side.

  44. Click here

    CONNECT TIE ROD END SUB-ASSEMBLY LH

    Click here

  45. Click here

    CONNECT TIE ROD END SUB-ASSEMBLY RH

    Tip:

    Use the same procedure described for the LH side.

  46. Click here

    CONNECT FRONT STABILIZER LINK ASSEMBLY LH

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  47. Click here

    CONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tip:

    Use the same procedure described for the LH side.

  48. Click here

    CONNECT FRONT SPEED SENSOR LH

    Click here

  49. Click here

    CONNECT FRONT SPEED SENSOR RH

    Tip:

    Use the same procedure described for the LH side.

  50. Click here

    INSTALL FRONT AXLE SHAFT NUT LH

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  51. Click here

    INSTALL FRONT AXLE SHAFT NUT RH

    Tip:

    Use the same procedure described for the LH side.

  52. Click here

    CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  53. Click here

    CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  54. Click here

    INSTALL COLUMN HOLE COVER SILENCER SHEET

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  55. Click here

    CONNECT CLUTCH HOSE (for Manual Transaxle)


    1. Connect the clutch hose and install the 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 clutch hose to the accumulator to flexible hose tube while holding the clutch hose.

      15 N*m 153 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.

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      • 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.

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

  56. Click here

    CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for CVT)


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

      5.0 N*m 51 kgf*cm 44 in.*lbf

    2. Connect the transmission control cable assembly to the transmission control cable support with the nut.

      12 N*m 122 kgf*cm 9 ft.*lbf

    3. Connect the transmission control cable assembly to the No. 1 transmission control cable bracket with a new clip.

    4. A01VAE0C01
      *a P Position
      *b N Position

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

    5. Connect the transmission control cable assembly to the control shaft lever with the nut.

      12 N*m 122 kgf*cm 9 ft.*lbf
  57. Click here

    CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)


    1. Connect the control cable to the control cable bracket, and install 2 new clips.

    2. Connect the control cable to the transaxle, and install the 2 washers and 2 clips.

  58. Click here

    INSTALL NO. 3 WATER BY-PASS HOSE (for CVT)


    1. Temporarily install the No. 3 water by-pass hose to the oil cooler assembly and heater water inlet hose.

    2. Attach the clamp and slide the 2 hose clamps to secure the hose.

  59. Click here

    CONNECT WIRE HARNESS AND HOSE


    1. Connect the heater water outlet hose and heater water inlet hose to the heater core and slide the 2 clamps to secure the hoses.

    2. Connect the connector tube hose to the air tube and slide the clamp to secure the hose.

    3. for Manual Transaxle:


      1. Attach the clamp and connect the engine wire to the manual transaxle with the bolt.

        19 N*m 194 kgf*cm 14 ft.*lbf

      2. Connect the starter wire to terminal B with the nut.

        9.8 N*m 100 kgf*cm 87 in.*lbf

      3. Attach the wire harness clamp and connect the terminal cap.

    4. for CVT:


      1. A01VB21C01
        *1 Engine Room Main Wire
        *2 Engine Wire

        Connect the engine wire and engine room main wire to the battery positive terminal with the nut as shown in the illustration.

        7.5 N*m 76 kgf*cm 66 in.*lbf

      2. Connect the connector to the battery current sensor.

      3. Connect the engine wire to the body with the bolt.

        11.4 N*m 116 kgf*cm 8 ft.*lbf

    5. Connect the wire harness and attach the 2 wire harness claws.

    6. Connect the 2 engine room junction block connectors and install the nut.

      12.8 N*m 131 kgf*cm 9 ft.*lbf

    7. Install the bolt and attach the 2 wire harness clamps.

      8.4 N*m 86 kgf*cm 74 in.*lbf
  60. Click here

    CONNECT FUEL TUBE SUB-ASSEMBLY


    1. Connect the fuel tube sub-assembly to the fuel pipe.

      Click here

  61. Click here

    CONNECT NO. 1 RADIATOR HOSE


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

  62. Click here

    INSTALL ECM

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  63. Click here

    INSTALL BATTERY BRACKET REINFORCEMENT

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  64. Click here

    INSTALL FRONT BATTERY BRACKET

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  65. Click here

    INSTALL RADIATOR HOSE SUB-ASSEMBLY

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  66. Click here

    INSTALL BATTERY TRAY

  67. Click here

    INSTALL BATTERY

  68. Click here

    INSTALL BATTERY CLAMP SUB-ASSEMBLY

    Click here

  69. Click here

    INSTALL AIR CLEANER CASE SUB-ASSEMBLY

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  70. Click here

    INSTALL AIR CLEANER CAP SUB-ASSEMBLY

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  71. Click here

    CONNECT COMPRESSOR ASSEMBLY WITH PULLEY


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

      9.8 N*m 100 kgf*cm 87 in.*lbf
    2. A01V7VIN01

      Install the 2 bolts and 2 nuts.

      25 N*m 255 kgf*cm 18 ft.*lbf
      Tip:

      Tighten the bolts and the nuts in the order shown in the illustration.

    3. Connect the connector and attach the wire harness clamp.

  72. Click here

    CONNECT NO. 2 RADIATOR HOSE

    Click here

  73. Click here

    INSTALL GENERATOR ASSEMBLY

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  74. Click here

    INSTALL V-RIBBED BELT

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  75. Click here

    INSTALL RADIATOR RESERVOIR ASSEMBLY


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

      5.0 N*m 51 kgf*cm 44 in.*lbf

    2. Connect the No. 1 and No. 2 water by-pass hoses to the radiator reservoir assembly, and slide the 2 hose clamps to secure the No. 1 and No. 2 water by-pass hose.

  76. Click here

    CONNECT CABLE TO POSITIVE BATTERY TERMINAL

  77. Click here

    CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

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

    Click here

  78. Click here

    ADD TRANSFER OIL

    Click here

  79. Click here

    ADD MANUAL TRANSAXLE OIL (for Manual Transaxle)

    Click here

  80. Click here

    ADD ENGINE OIL

    Click here

  81. Click here

    ADD ENGINE COOLANT

    Click here

  82. Click here

    ADD CONTINUOUSLY VARIABLE TRANSAXLE FLUID (for CVT)

    Click here

  83. Click here

    INSPECT SHIFT LEVER POSITION (for CVT)

    Click here

  84. Click here

    INSPECT FOR FUEL LEAK

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  85. Click here

    INSPECT FOR COOLANT LEAK

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  86. Click here

    INSPECT FOR OIL LEAK

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  87. Click here

    INSPECT FOR EXHAUST GAS LEAK

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  88. Click here

    INSPECT IGNITION TIMING

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  89. Click here

    INSPECT ENGINE IDLE SPEED

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  90. Click here

    INSPECT CO/HC

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  91. Click here

    ADJUST FRONT WHEEL ALIGNMENT

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  92. Click here

    INSTALL NO. 2 ENGINE UNDER COVER


    1. Install the No. 2 engine under cover with the bolt and clip.

      5.5 N*m 56 kgf*cm 49 in.*lbf
  93. Click here

    INSTALL FRONT FLOOR COVER

    Click here

  94. Click here

    INSTALL REAR ENGINE UNDER COVER RH


    1. Install the rear engine under cover RH with the 3 clips.

  95. Click here

    INSTALL REAR ENGINE UNDER COVER LH


    1. for Half Cover Type:

      Install the rear engine under cover LH with the 3 clips.

    2. for Full Cover Type:

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

  96. Click here

    INSTALL NO. 1 ENGINE UNDER COVER

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  97. Click here

    INSTALL NO. 2 CYLINDER HEAD COVER

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  98. Click here

    RESET MEMORY (for CVT)

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