INSTALL ENGINE HANGER
INSTALL FRONT ENGINE MOUNTING INSULATOR
Perform this procedure only when replacement of the front engine mounting insulator is necessary.
Install the 2 front engine mounting insulator to the 2 front No. 1 engine mounting brackets with the 2 nuts.
INSTALL FRONT ENGINE MOUNTING HEAT INSULATOR RH
Install the front engine mounting heat insulator RH to the front engine mounting insulator with the bolt.
INSTALL ENGINE WIRE
Install the engine wire to the engine assembly.
REMOVE ENGINE FROM ENGINE STAND
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.
Attach the engine sling device and hang the engine assembly with the chain block.
Remove the engine assembly from the engine stand.
INSTALL ENGINE ASSEMBLY
Perform "Inspection After Repair" after replacing the engine assembly.
Slowly lower the engine assembly into the engine compartment.
Install the engine assembly to the body with the 4 bolts and 4 nuts.
Make sure to tighten the side with the nut.
When installing a bolt with a claw (stopper), make sure to install the bolt with the claw (stopper) as shown in the illustration so that a clearance is maintained between the claw (stopper) and the intermediate shaft.
Front Engine Mounting Insulator
Remove the 2 bolts and 2 engine hangers.
INSTALL REAR END PLATE
Install the rear end plate to the cylinder block with the bolt.
Connect the No. 1 water by-pass pipe to the rear end plate with the bolt.
INSTALL FLYWHEEL SUB-ASSEMBLY
INSTALL CLUTCH DISC ASSEMBLY
INSTALL CLUTCH COVER ASSEMBLY
INSPECT AND ADJUST CLUTCH COVER ASSEMBLY
INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY
INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY
INSTALL PROPELLER SHAFT GUARD
INSTALL FRONT EXHAUST PIPE ASSEMBLY
CONNECT ENGINE WIRE
Connect the sensor bracket to the right side of the frame with the bolt.
Connect the air fuel ratio sensor connector.
Connect the wire clamp to the front engine mounting bracket LH with the bolt.
Connect the 2 connectors to the engine room relay block.
Attach the clamp.
Connect the engine wire to the engine room relay block with the nut.
Attach the 2 claws and install the No. 1 relay block cover side to the engine room relay block.
Attach the 3 claws and install the No. 1 relay block cover upper to the engine room relay block.
Attach the clamp and install the No. 2 engine wire with the bolt.
Position the No. 2 engine wire as shown in the illustration.
Attach the 2 clamps and connect the No. 2 engine wire with the 2 bolts.
Install the battery tray.
Install the battery.
Install the battery hold down clamp with the 2 nuts.
Tighten the nut and install the positive (+) battery terminal.
Position the positive (+) battery terminal as shown in the illustration.
Connect the engine room main wire to the positive (+) battery terminal with the nut.
Connect the connector to the engine room main wire.
Push the engine wire through the dash panel into the cabin.
The wire should be within the range shown in the illustration.
Connect the engine wire with the bolt.
Attach the 2 clamps and connect the 3 connectors to the instrument panel wire.
INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY
CONNECT NO. 1 FUEL HOSE
CONNECT NO. 2 FUEL HOSE
CONNECT UNION TO CONNECTOR TUBE HOSE
Connect the union to connector tube hose to the intake manifold, and slide the clip to secure the hose.
CONNECT PURGE LINE HOSE
Connect the purge line hose to the purge VSV, and slide the clip to secure the hose.
INSTALL STARTER ASSEMBLY
for DENSO Made:
for BOSCH Made:
CONNECT COOLER COMPRESSOR ASSEMBLY (w/ Air Conditioning System)
INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
Install a new O-ring and the engine oil level dipstick guide with the bolt.
INSTALL ENGINE OIL LEVEL DIPSTICK
CONNECT VANE PUMP ASSEMBLY
Connect the vane pump assembly with the 2 bolts.
Connect the power steering oil pressure switch connector.
CONNECT HEATER HOSE
Connect the heater water outlet hose to the heater radiator unit sub-assembly, and slide the clamp to secure the hose.
Connect the heater water inlet hose to the heater radiator unit sub-assembly, and slide the clamp to secure the hose.
INSTALL RADIATOR ASSEMBLY
INSTALL FAN SHROUD
INSTALL RADIATOR RESERVOIR
INSTALL RADIATOR HOSE OUTLET
INSTALL RADIATOR HOSE INLET
INSTALL NO. 1 RADIATOR AIR GUIDE
INSTALL RADIATOR SIDE DEFLECTOR LH
for Resin Type Bumper:
for Steel Type Bumper:
INSTALL RADIATOR SIDE DEFLECTOR RH
Use the same procedure described for the LH side.
INSTALL INTAKE AIR CONNECTOR
INSTALL AIR CLEANER CASE SUB-ASSEMBLY
Install the air cleaner case sub-assembly with the 3 bolts.
Attach the 3 wire harness clamps.
INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
Install the air cleaner filter element sub-assembly to the air cleaner cap sub-assembly.
INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH NO. 1 AIR CLEANER HOSE
Install the air cleaner cap sub-assembly with No. 1 air cleaner hose and tighten the hose clamp.
Attach the 4 clamps.
Connect the intake mass air flow meter connector and attach the 2 wire harness clamps.
INSTALL HOOD SUB-ASSEMBLY
Install the hood sub-assembly to the 2 hood hinge assemblies with the 4 bolts.
Connect the washer nozzle hose to the hood sub-assembly.
Adjust the hood sub-assembly.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
ADD ENGINE OIL
ADD ENGINE COOLANT
ADD MANUAL TRANSMISSION OIL
INSPECT FOR FUEL LEAK
INSPECT FOR OIL LEAK
INSPECT FOR COOLANT LEAK
INSPECT FOR EXHAUST GAS LEAK
INSPECT IGNITION TIMING
INSPECT ENGINE IDLE SPEED
CHECK THROTTLE BODY WITH MOTOR ASSEMBLY
INSTALL NO. 1 ENGINE UNDER COVER (w/ Cover)
INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY (w/ Cover)
INSTALL FRONT FENDER SEAL LH
Install the front fender seal LH with the 5 new clips.
INSTALL FRONT FENDER SEAL RH
Install the front fender seal RH with the 5 new clips.
INSTALL FRONT UPPER FENDER APRON SEAL LH
Install the front upper fender apron seal LH with the 6 new clips.
INSTALL FRONT UPPER FENDER APRON SEAL RH
Install the front upper fender apron seal RH with the 6 new clips.