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
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.
Install the engine mounting insulator sub-assembly RH with the 3 bolts.
INSTALL ENGINE MOUNTING INSULATOR LH
Tech Tips
Perform this procedure only when replacement of the engine mounting insulator LH is necessary.
Install the engine mounting insulator LH with the 4 bolts.
INSTALL REAR ENGINE MOUNTING INSULATOR
Tech Tips
Perform this procedure only when replacement of the rear engine mounting insulator is necessary.
Install the rear engine mounting insulator with the 2 bolts and 2 nuts in the order shown in the illustration.
INSTALL ENGINE HANGER
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.
Install a sling device and chain block to the engine and hang the engine.
Remove the engine from the engine stand.
FIX ENGINE ASSEMBLY
INSTALL FLYWHEEL WITH DAMPER ASSEMBLY
Using SST, hold the crankshaft pulley.
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.
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.
INSTALL CLUTCH DISC ASSEMBLY
INSTALL CLUTCH COVER ASSEMBLY
INSPECT AND ADJUST CLUTCH COVER ASSEMBLY
INSTALL MANUAL TRANSAXLE ASSEMBLY
for 2WD:
for 4WD:
INSTALL STIFFENER PLATE LH
Temporarily install the stiffener plate LH with the 4 bolts.
While holding the stiffener plate LH against the transaxle, tighten bolt A, and then tighten bolts B, C and D.
INSTALL STIFFENER PLATE RH
Temporarily install the stiffener plate RH with the 4 bolts.
While holding the stiffener plate RH against the transaxle, tighten bolt A, and then tighten bolts B, C and D.
INSTALL OIL PAN INSULATOR
Install the oil pan insulator with the 2 bolts.
INSTALL ENGINE MOUNTING BRACKET LH
Tech Tips
Perform this procedure only when replacement of the engine mounting bracket LH is necessary.
Install the engine mounting bracket LH with the 4 bolts.
INSTALL REAR ENGINE MOUNTING BRACKET
for 2WD:
Temporarily install the rear engine mounting bracket with the 5 bolts.
Tighten the 5 bolts of the rear engine mounting bracket in the order shown in the illustration.
for 4WD:
Temporarily install the rear engine mounting bracket with the 4 bolts.
Tighten the 4 bolts of the rear engine mounting bracket in the order shown in the illustration.
INSTALL FRONT ENGINE MOUNTING BRACKET
Temporarily install the front engine mounting bracket with the 3 bolts.
Tighten the 3 bolts of the front engine mounting bracket in the order shown in the illustration.
INSTALL ENGINE WIRE
INSTALL STARTER ASSEMBLY
w/ Stop And Sart System:
w/o Stop And Start System:
INSTALL NO. 1 AIR TUBE
Install the No. 1 air tube with the 2 bolts and tighten the clamp.
Note
Before installation, remove any oil residue from the inside of the No. 1 air tube and air hose.
INSTALL ENGINE WITH TRANSAXLE
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.
Temporarily install the front suspension member with the through bolt.
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.
Temporarily install the front suspension member rear brace RH and front suspension member rear brace LH with the 6 bolts.
Temporarily install the 2 bolts to the front suspension member sub-assembly.
Connect the engine mounting insulator LH with the bolt and nut.
Tech Tips
While holding the bolt in place, tighten the nut.
Connect the engine mounting insulator sub-assembly RH with the 2 bolts and 2 nuts.
Tighten the 8 bolts.
Install the front crossmember sub-assembly with the 6 bolts.
Remove the 2 bolts, No. 1 engine hanger and No. 2 engine hanger.
Install the front suspension member sub-assembly with the through bolt.
Install the front engine mounting insulator with the through bolt and nut.
Note
While holding the nut in place, tighten the through bolt.
INSTALL FUEL HOSE PROTECTOR
Install the fuel hose protector to the cylinder head sub-assembly.
INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH
Install the front suspension member reinforcement LH with the 4 bolts.
INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH
INSTALL FRONT LOWER ENGINE MOUNTING BRACKET REINFORCEMENT
Install the front lower engine mounting bracket reinforcement with the 2 bolts.
INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
INSTALL FRONT AXLE ASSEMBLY LH
INSTALL FRONT AXLE ASSEMBLY RH
Tech Tips
Perform the same procedure as for the LH side.
CONNECT FRONT STABILIZER LINK ASSEMBLY LH
CONNECT FRONT STABILIZER LINK ASSEMBLY RH
Tech Tips
Perform the same procedure as for the LH side.
INSTALL FRONT AXLE SHAFT NUT LH
INSTALL FRONT AXLE SHAFT NUT RH
Tech Tips
Perform the same procedure as for the LH side.
INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY
CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY
INSTALL COLUMN HOLE COVER SILENCER SHEET
CONNECT CLUTCH RELEASE CYLINDER ASSEMBLY
Connect the clutch release cylinder assembly and clutch flexible hose bracket with the 4 bolts.
CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
Connect the transmission control cable assembly to the transmission control cable bracket with 2 new clips.
Install the 2 pins.
CONNECT SUCTION HOSE SUB-ASSEMBLY
Sufficiently apply compressor oil to a new O-ring and the fitting surface of the hose joint.
Compressor Oil |
---|
ND-OIL 8 or equivalent |
Install the O-ring to the suction hose sub-assembly.
Connect the suction hose sub-assembly to the cooler compressor assembly with the bolt.
Connect the connector to the cooler compressor assembly.
CONNECT DISCHARGE HOSE SUB-ASSEMBLY
Sufficiently apply compressor oil to a new O-ring and the fitting surface of the hose joint.
Compressor Oil |
---|
ND-OIL 8 or equivalent |
Install the O-ring to the discharge hose sub-assembly.
Connect the discharge hose sub-assembly to the cooler compressor assembly with the bolt.
INSTALL RADIATOR RESERVOIR ASSEMBLY
Install the radiator reservoir assembly with the 2 bolts.
Connect the water by-pass hose to the radiator reservoir assembly, and slide the clamp to secure the hose.
CONNECT NO. 2 WATER BY-PASS HOSE
Connect the No. 2 water by-pass hose to the No. 4 water by-pass pipe, and slide the clamp to secure the hose.
CONNECT NO. 2 RADIATOR HOSE
Connect the No. 2 radiator hose to the water inlet housing, and slide the clamp to secure the hose.
INSTALL INTERCOOLER AIR HOSE
CONNECT RADIATOR HOSE SUB-ASSEMBLY
Connect the radiator hose sub-assembly to the cylinder head sub-assembly and slide the clamp to secure the hose.
CONNECT OUTLET HEATER WATER HOSE
Connect the outlet heater water hose to the No. 3 water by-pass pipe and slide the clamp to secure the hose.
CONNECT INLET HEATER WATER HOSE
Connect the inlet heater water hose to the cylinder head sub-assembly and slide the clamp to secure the hose.
CONNECT HOSES AND CONNECTORS
Connect the vacuum pump hose to the vacuum pump assembly and slide the clip to secure the hose.
Install the injector driver assembly with the 2 nuts.
Connect the 4 injector driver connectors and attach the 2 wire harness clamps.
Attach the 3 wire harness clamps to the 3 wire harness clamp brackets.
Install the bolt to the manual transaxle assembly.
Connect the 2 connectors and attach the wire harness clamp.
Install the ground cable with the bolt and attach the wire harness clamp.
Install the bolt to the wire harness clamp bracket.
Connect the starter wire with the nut.
Install the bolt and attach the engine wire cover clamp and engine wire harness clamp.
Connect the 2 connectors to the No. 8 engine wire.
Attach the 2 claws and connect the engine wire to the engine room No. 1 relay block with the nut.
Connect the 3 connectors to the engine room No. 1 relay block.
Install the engine room relay block and junction block cover.
INSTALL ECM
INSTALL AIR CLEANER BRACKET
Install the air cleaner bracket with the 3 bolts.
Connect the 2 fuel hoses to the air cleaner bracket.
Attach the 3 wire harness clamps.
Connect the glow plug relay and level warning switch connector.
INSTALL FUEL FILTER ASSEMBLY
Install the fuel filter assembly to the air cleaner bracket with the bolt.
Connect the 2 fuel hoses to the fuel filter assembly and slide the clamp to secure the hoses.
INSTALL AIR CLEANER SUPPORT
Install the air cleaner support with the 2 nuts.
INSTALL AIR CLEANER CASE
Install the air cleaner case with the 3 bolts.
INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
INSTALL AIR CLEANER CAP SUB-ASSEMBLY
Install the air cleaner cap sub-assembly and attach the 3 clips.
Connect the mass air flow meter connector and wire harness clamp.
Connect the air cleaner hose and tighten the hose clamp.
Connect the PCV hose.
INSTALL NO. 3 AIR HOSE
CONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY
INSTALL BATTERY BRACKET REINFORCEMENT
Install the battery bracket reinforcement with the 2 bolts.
INSTALL FRONT BATTERY BRACKET
Install the front battery bracket with the 4 bolts.
Attach the 2 wire harness clamps.
INSTALL BATTERY TRAY
INSTALL BATTERY
INSTALL BATTERY INSULATOR
INSTALL BATTERY CLAMP SUB-ASSEMBLY
Attach the hook of the battery clamp sub-assembly to the front battery bracket.
Partially tighten the nut and temporarily install the bolt.
Attach the 2 wire harness clamps.
Adjust the battery clamp position.
Tighten the nut and bolt.
INSTALL DIFFERENTIAL PRESSURE SENSOR ASSEMBLY
INSTALL FRONT EXHAUST PIPE ASSEMBLY
ADD MANUAL TRANSAXLE OIL
for 2WD:
for 4WD:
ADD ENGINE OIL
CONNECT CABLE TO POSITIVE BATTERY TERMINAL
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Note
When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
ADD ENGINE COOLANT
BLEED AIR FROM FUEL SYSTEM
CHARGE REFRIGERANT
WARM UP ENGINE
INSPECT FOR REFRIGERANT LEAK
PERFORM REGISTRATION
Perform registration of the injector compensation codes.
Perform registration of the pilot quantity learning.
PERFORM INITIALIZATION
Perform initialization of the crank time compensation reset function.
PERFORM THROTTLE VALVE FULLY CLOSED POSITION LEARNING
INSPECT FOR OIL LEAK
INSPECT FOR COOLANT LEAK
INSPECT FOR FUEL LEAK
INSPECT FOR EXHAUST GAS LEAK
INSPECT FOR MANUAL TRANSAXLE OIL LEAK
INSTALL REAR ENGINE UNDER COVER RH
INSTALL REAR ENGINE UNDER COVER LH
Install the rear engine under cover LH with the 2 clips.
INSTALL FRONT FLOOR COVER RH
Install the front floor cover RH with the 3 nuts and 3 clips.
INSTALL NO. 2 ENGINE UNDER COVER
Install the No. 2 engine under cover with the bolt and clip.
INSTALL FRONT FLOOR COVER
INSTALL NO. 1 ENGINE UNDER COVER
Install the No. 1 engine under cover with the 11 clips.
Install the 4 bolts and 2 screws.
INSTALL NO. 1 ENGINE COVER
Attach the 4 clips to install the No. 1 engine cover.
CHECK IDLE SPEED
CHECK MAXIMUM ENGINE SPEED
ADJUST FRONT WHEEL ALIGNMENT
CHECK ABS SPEED SENSOR SIGNAL