ENGINE ASSEMBLY(w/o Glow Plug Controller) INSTALLATION

CAUTION / NOTICE / HINT

Note:

  • When the manual transaxle assembly or multi-mode 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 or multi-mode manual transaxle assembly 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.

  • "Injector Compensation" and "Pilot Quantity Learning Values Reset" functions using the GTS.

    Click here

PROCEDURE

  1. 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.

  2. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    Click here

  3. INSTALL FLYWHEEL SUB-ASSEMBLY

    Click here

  4. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)

    Click here

  5. INSTALL CLUTCH DISC ASSEMBLY (for Multi-Mode Manual Transaxle)

    Click here

  6. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)

    Click here

  7. INSTALL CLUTCH COVER ASSEMBLY (for Multi-Mode Manual Transaxle)

    Click here

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

    Click here

  9. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Multi-Mode Manual Transaxle)

    Click here

  10. INSTALL CRANK POSITION SENSOR

    Click here

  11. INSTALL CYLINDER BLOCK SIDE COVER

    1. Install the cylinder block side cover with the bolt and washer plate.

      7.0 N*m

      71 kgf*cm

      62 in.*lbf

  12. INSTALL EXHAUST MANIFOLD

    Click here

  13. TEMPORARILY INSTALL INLET TURBO OIL PIPE SUB-ASSEMBLY

    Click here

  14. INSTALL TURBOCHARGER SUB-ASSEMBLY

    Click here

  15. INSTALL INLET TURBO OIL PIPE SUB-ASSEMBLY

    Click here

  16. INSTALL MANIFOLD STAY

    Click here

  17. INSTALL TURBOCHARGER STAY

    Click here

  18. INSTALL NO. 2 MANIFOLD SUPPORT BRACKET

    1. Install the No. 2 manifold support bracket with the 2 bolts.

      37 N*m

      377 kgf*cm

      27 ft.*lbf

  19. INSTALL MANIFOLD SUPPORT BRACKET

    1. Install the manifold support bracket with the 3 bolts.

      37 N*m

      377 kgf*cm

      27 ft.*lbf

  20. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    1. Install a new gasket to the turbocharger.

    2. Temporarily install the exhaust manifold converter sub-assembly with 3 new nuts and a new bolt.

    3. Fully tighten the 3 nuts first, and then tighten the bolt.

      Nut

      26 N*m

      265 kgf*cm

      19 ft.*lbf

      Bolt

      37 N*m

      377 kgf*cm

      27 ft.*lbf

    4. Engage the 2 harness clamps to the harness bracket.

    5. Engage the 2 harness clamps to the No. 2 timing chain cover.

    6. Connect the 2 exhaust gas temperature sensor connectors.

  21. INSTALL NO. 2 EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Click here

  22. INSTALL NO. 3 MANIFOLD SUPPORT BRACKET

    Click here

  23. INSTALL NO. 4 MANIFOLD SUPPORT BRACKET

    Click here

  24. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

    Click here

  25. INSTALL NO. 2 VACUUM PIPE

    Click here

  26. INSTALL NO. 1 TURBO INSULATOR

    1. Install the No. 1 turbo insulator with the 3 bolts.

      7.0 N*m

      71 kgf*cm

      62 in.*lbf

  27. INSTALL SENSOR BRACKET

    1. Install the sensor bracket with the nut.

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

    2. Connect the 2 vacuum transmitting hoses and slide the 2 clips to secure them.

  28. INSTALL HARNESS BRACKET

    1. w/o No. 1 Engine Cover:

      1. Install the 2 harness brackets with the 2 nuts.

        11 N*m

        112 kgf*cm

        8 ft.*lbf

    2. w/ No. 1 Engine Cover:

      1. Install the No. 2 engine cover bracket and 2 harness brackets with the 2 nuts.

        11 N*m

        112 kgf*cm

        8 ft.*lbf

  29. INSTALL OUTLET HEATER WATER HOSE A

    1. Install the outlet heater water hose A to the outlet outer water sub-assembly and slide the clip to secure it.

  30. INSTALL NO. 2 AIR TUBE

    1. A295929C01

      *a

      View A

      *b

      LH

      *c

      Rear

      Connect the No. 2 air tube to the diesel throttle body assembly with the hose clamp as shown in the illustration.

      6.5 N*m

      66 kgf*cm

      58 in.*lbf

      Note:

      One minute after tightening the hose clamp, check that residual torque is 3.2 N*m (33 kgf*cm, 28 in.*lbf) or more.

    2. Install the No. 2 air tube with the 2 bolts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  31. INSTALL ENGINE WIRE

    1. Install the engine wire to the engine.

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

    Click here

  33. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY (for Multi-Mode Manual Transaxle)

    Click here

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

    Click here

  35. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Multi-Mode Manual Transaxle)

    Click here

  36. INSPECT CLUTCH PIPE LINE (for Manual Transaxle)

    Click here

  37. INSPECT CLUTCH PIPE LINE (for Multi-Mode Manual Transaxle)

    Click here

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

    Click here

  39. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Multi-Mode Manual Transaxle)

    Click here

  40. INSTALL ACCUMULATOR TO FLEXIBLE HOSE TUBE (for Manual Transaxle)

    Click here

  41. INSTALL BLEEDER CLUTCH RELEASE TUBE (for Multi-Mode Manual Transaxle)

    Click here

  42. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

    Click here

  43. INSTALL MULTI-MODE MANUAL TRANSAXLE ASSEMBLY (for Multi-Mode Manual Transaxle)

    Click here

  44. CONNECT WIRE HARNESS (for Manual Transaxle)

  45. CONNECT WIRE HARNESS (for Multi-Mode Manual Transaxle)

    Click here

  46. INSTALL STARTER ASSEMBLY (w/o Stop And Start System)

    Click here

  47. INSTALL STARTER ASSEMBLY (w/ Stop And Start System)

    Click here

  48. INSTALL NO. 1 AIR TUBE

  49. INSTALL ENGINE MOUNTING INSULATOR LH

    Tip:

    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.

      95 N*m

      969 kgf*cm

      70 ft.*lbf

  50. 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. Install the engine mounting insulator sub-assembly RH with the 3 bolts.

      95 N*m

      969 kgf*cm

      70 ft.*lbf

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

    3. Install the cooler pipe clamp bracket with the bolt.

      9.8 N*m

      100 kgf*cm

      87 in.*lbf

    4. Install the radiator reserve tank assembly with the 2 bolts.

      5.0 N*m

      51 kgf*cm

      44 in.*lbf

  51. TEMPORARILY TIGHTEN REAR ENGINE MOUNTING INSULATOR

    1. Temporarily install the rear engine mounting insulator with the bolt.

  52. TEMPORARILY TIGHTEN FRONT ENGINE MOUNTING INSULATOR

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

  53. 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. 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:

      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.

      56 N*m

      571 kgf*cm

      41 ft.*lbf

      Tip:

      When tightening the through bolt, keep the nut from rotating.

    4. A295927N01

      Install the engine mounting insulator sub-assembly RH with the 3 nuts.

      Nut A

      95 N*m

      969 kgf*cm

      70 ft.*lbf

      Nut B

      52 N*m

      530 kgf*cm

      38 ft.*lbf

    5. Install the front crossmember sub-assembly with the 4 bolts.

      99 N*m

      1010 kgf*cm

      73 ft.*lbf

    6. Connect the front engine mounting insulator to the front crossmember sub-assembly with the 2 bolts.

      95 N*m

      969 kgf*cm

      70 ft.*lbf

  54. REMOVE ENGINE HANGERS

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

  55. INSTALL NO. 1 CLUTCH HOSE (for Manual Transaxle)

    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 accumulator to flexible hose tube.

      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

  56. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

  57. INSTALL FRONT SUSPENSION MEMBER REAR BRACE LH

    Click here

  58. INSTALL FRONT SUSPENSION MEMBER REAR BRACE RH

    Tip:

    Perform the same procedure as for the LH side.

  59. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH

    Click here

  60. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Click here

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

    Click here

  62. INSTALL REAR ENGINE MOUNTING INSULATOR

    1. Install the rear engine mounting insulator with the bolt.

      95 N*m

      969 kgf*cm

      70 ft.*lbf

  63. INSTALL FRONT ENGINE MOUNTING INSULATOR

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

      85 N*m

      867 kgf*cm

      63 ft.*lbf

      Tip:

      When tightening the through bolt, keep the nut from rotating.

  64. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  65. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

    Click here

  66. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  67. INSTALL FRONT CENTER FLOOR BRACE SUB-ASSEMBLY

    Click here

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

    Click here

  69. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  70. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

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

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

      9.8 N*m

      100 kgf*cm

      87 in.*lbf

    2. A295926N01

      Install the compressor assembly with pulley with the 2 bolts and 2 nuts.

      25 N*m

      255 kgf*cm

      18 ft.*lbf

      Tip:

      Tighten the bolts and nuts in the order shown in the illustration to install the compressor assembly with pulley.

    3. Connect the connector.

  72. INSTALL V-RIBBED BELT

    Click here

  73. INSPECT V-RIBBED BELT

    Click here

  74. CONNECT OUTLET HEATER WATER HOSE

    1. Connect the outlet heater water hose to the water by-pass pipe sub-assembly and slide the clip to secure it.

  75. CONNECT INLET HEATER WATER HOSE A (w/o Combustion Type Power Heater)

    1. Connect the inlet heater water hose A to the inlet heater water pipe A and slide the clip to secure it.

  76. CONNECT INLET HEATER WATER HOSE D (w/ Combustion Type Power Heater)

    1. Connect the inlet heater water hose D to the inlet heater water pipe A and slide the clip to secure it.

  77. CONNECT NO. 1 RADIATOR HOSE

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

  78. CONNECT NO. 2 RADIATOR HOSE

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

  79. CONNECT WATER BY-PASS HOSE

    1. Connect the water by-pass hose to the water inlet and slide the clip to secure it.

  80. CONNECT UNION TO CONNECTOR TUBE HOSE

    1. Connect the union to connector tube hose to the cylinder head cover sub-assembly and slide the clip to secure it.

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

    1. Install the transmission control cable assembly to the rear engine mounting bracket with the bolt.

      5.0 N*m

      51 kgf*cm

      44 in.*lbf

    2. Install the 2 transmission control cable assemblies to the control cable bracket assembly with 2 new clips.

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

  82. INSTALL INTERCOOLER AIR HOSE

    1. A295924C01

      *a

      View A

      *b

      View B

      *c

      Upper

      *d

      Front

      Install the intercooler air hose with the 2 hose clamps as shown in the illustration.

      6.5 N*m

      66 kgf*cm

      58 in.*lbf

      Note:

      One minute after tightening the hose clamps, check that the residual torque is 3.2 N*m (33 kgf*cm, 28 in.*lbf) or more.

  83. INSTALL NO. 3 AIR HOSE

    1. A295928C01

      *a

      View A

      *b

      View B

      *c

      LH

      *d

      Front

      *e

      Upper

      *f

      RH

      Install the No. 3 air hose with the 2 hose clamps as shown in the illustration.

      6.5 N*m

      66 kgf*cm

      58 in.*lbf

      Note:

      One minute after tightening the hose clamps, check that the residual torque is 3.2 N*m (33 kgf*cm, 28 in.*lbf) or more.

  84. INSTALL NO. 2 BATTERY CARRIER

    1. Install the No. 2 battery carrier with the 4 bolts.

      18.5 N*m

      189 kgf*cm

      14 ft.*lbf

  85. INSTALL AIR CLEANER BRACKET

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

      7.0 N*m

      71 kgf*cm

      62 in.*lbf

  86. INSTALL FUEL FILTER SUPPORT

    1. Install the fuel filter support with the 3 bolts.

      17.5 N*m

      178 kgf*cm

      13 ft.*lbf

    2. Connect the wire harness clamp to the fuel filter support.

  87. INSTALL GLOW PLUG RELAY ASSEMBLY

    1. Install the glow plug relay assembly to the fuel filter support with the bolt.

      11 N*m

      112 kgf*cm

      8 ft.*lbf

    2. Connect the wire harness clamp to the fuel filter support.

  88. CONNECT WIRE HARNESS (for Multi-Mode Manual Transaxle)

    1. Connect the 7 connectors.

    2. Connect the 6 wire harness clamps.

  89. CONNECT WIRE HARNESS

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

      12.5 N*m

      127 kgf*cm

      9 ft.*lbf

    2. Connect the 2 wire harness clamps.

    3. Connect the 4 wire harness connectors and wire harness to the engine room junction block with the 2 claws.

    4. Install the 2 nuts to the engine room relay block and junction block assembly.

      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 3 wire harness clamps to the fuel filter support.

    7. Lower the lever to connect the ECM connector.

  90. INSTALL FUEL FILTER ASSEMBLY

    Click here

  91. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    1. Install the air cleaner case sub-assembly with the 3 bolts.

      7.0 N*m

      71 kgf*cm

      62 in.*lbf

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

  92. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    1. Install the air cleaner cap sub-assembly with the hose clamp.

    2. Lock the 2 lock clamps.

    3. Connect the wire harness clamp, connector and ventilation hose.

  93. INSTALL BATTERY

    1. Install the battery tray.

    2. Set the battery to the battery tray.

    3. Install the battery clamp sub-assembly and battery clamp bolt with the bolt and nut.

      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 (+) battery terminal.

      5.4 N*m

      55 kgf*cm

      48 in.*lbf

  94. INSTALL OUTER COWL TOP PANEL (for LHD)

    Click here

  95. INSTALL OUTER COWL TOP PANEL (for RHD)

    Click here

  96. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    1. Connect the cable to the negative (-) battery terminal.

      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

  97. ADD MANUAL TRANSAXLE OIL (for Manual Transaxle)

    Click here

  98. ADD MANUAL TRANSAXLE OIL (for Multi-Mode Manual Transaxle)

    Click here

  99. ADD ENGINE OIL

    Click here

  100. ADD ENGINE COOLANT

    Click here

  101. BLEED CLUTCH LINE (for Manual Transaxle)

    Click here

  102. BLEED CLUTCH LINE (for Multi-Mode Manual Transaxle)

    Click here

  103. BLEED AIR FROM FUEL SYSTEM

    Click here

  104. INSPECT FOR TRANSAXLE OIL LEAK

  105. INSPECT ENGINE OIL LEVEL

    Click here

  106. INSPECT FOR COOLANT LEAK

    Click here

  107. INSPECT FOR FUEL LEAK

    Click here

  108. INSPECT FOR EXHAUST GAS LEAK

  109. INSPECT FOR OIL LEAK

    Click here

  110. INSTALL NO. 1 ENGINE COVER (w/ No. 1 Engine Cover)

    1. A295799C01
      V100136

      Engage the 2 hooks first.
      V100135

      Engage the 2 grommets next.

      Engage the 2 hooks to the bracket. Then align the 2 grommets with the 2 pins, and press down on the No. 1 engine cover to attach the pins.

  111. INSTALL REAR ENGINE UNDER COVER LH

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

  112. INSTALL REAR ENGINE UNDER COVER RH

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

  113. INSTALL FRONT NO. 3 ENGINE UNDER COVER (for Full Cover Type)

    1. Install the front No. 3 engine under cover with the 4 clips.

  114. INSTALL CENTER NO. 4 ENGINE UNDER COVER (for Half Cover Type)

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

  115. INSTALL CENTER NO. 4 ENGINE UNDER COVER (for Full Cover Type)

    1. Install the center No. 4 engine under cover with the 2 clips.

  116. 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.

  117. INSTALL NO. 1 ENGINE UNDER COVER (for Full Cover Type)

    1. Install the No. 1 engine under cover with the 2 bolts and 11 clips.

  118. INSTALL FRONT LOWER BUMPER ABSORBER

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

  119. INSTALL FRONT WHEELS

    103 N*m

    1050 kgf*cm

    76 ft.*lbf

  120. ADJUST FRONT WHEEL ALIGNMENT

    Click here

  121. PERFORM INITIALIZATION OF MULTI-MODE MANUAL TRANSAXLE SYSTEM (for Multi-Mode Manual Transaxle)

    Click here

  122. PERFORM LEARNING OF MULTI-MODE MANUAL TRANSAXLE SYSTEM (for Multi-Mode Manual Transaxle)

    Click here

  123. PERFORM SYNCHRONIZATION POSITION CALIBRATION (for Multi-Mode Manual Transaxle)

    Click here

  124. CHECK ABS SPEED SENSOR SIGNAL

    Click here