CAUTION / NOTICE / HINT
CAUTION:
As the engine assembly with transaxle assembly 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 LH
Tech Tips
Perform this procedure only when replacement of the engine mounting insulator LH is necessary.
Install the engine mounting insulator LH to the vehicle body with the 4 bolts.
TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR
Temporarily install the front engine mounting insulator with the bolt and nut.
TEMPORARILY INSTALL REAR ENGINE MOUNTING INSULATOR
Temporarily install the rear engine mounting insulator with the bolt.
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 assembly while it is suspended, as doing so is dangerous.
Install a sling device and chain block to the engine assembly and hang the engine assembly.
Remove the engine assembly from the engine stand.
INSTALL MANUAL TRANSAXLE ASSEMBLY
Make sure that the dowel pins are not loose, bent, damaged or scratched.
Align the input shaft with the clutch disc assembly and install the engine assembly to the transaxle.
Temporarily install the engine assembly with the 6 bolts.
Note
Be extremely careful that the vehicle body, clutch pipe line and radiator cooling fan do not interfere with the manual transaxle assembly when installing the manual transaxle assembly.
Make sure that the wire harness or similar items are not pinched between the contact surfaces.
Do not forcibly pry on the manual transaxle assembly when installing it to the engine assembly.
Before tightening the bolts, insert the dowel pins into the dowel holes securely so that the end face of the transaxle assembly fits close against the engine assembly.
Do not apply excessive force to the manual transaxle assembly as this will break the input shaft.
Make sure that the contact surfaces of the engine assembly and manual transaxle assembly are flat against each other before tightening the bolts.
TEMPORARILY INSTALL NO. 2 MANIFOLD STAY
TEMPORARILY INSTALL STARTER ASSEMBLY
TIGHTEN ENGINE AND TRANSAXLE CONNECTING BOLT
INSTALL NO. 1 CLUTCH HOUSING COVER
INSTALL NO. 1 AIR TUBE ASSEMBLY
Install the No. 1 air tube assembly to the manual transaxle assembly with the 2 bolts.
Connect the No. 4 water by-pass hose to the EGR cooler assembly.
Connect the compressor outlet elbow to the turbocharger sub-assembly.
INSTALL ENGINE WIRE
Connect the connectors, attach the clamps and install the engine wire to the engine assembly with the bracket bolts.
INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
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.
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.
Install the engine mounting insulator LH with the bolt and nut.
Tech Tips
When tightening the through bolt, keep the nut from rotating.
Install the engine mounting insulator sub-assembly RH with the 4 bolts and 3 nuts.
Attach the 2 clamps and connect the suction pipe sub-assembly.
Attach the clamp and connect the air conditioner tube and accessory assembly.
Install the front crossmember sub-assembly with the 4 bolts.
Connect the front engine mounting insulator to the front crossmember sub-assembly with the 2 bolts.
INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
INSTALL FRONT SUSPENSION MEMBER REAR BRACE LH
INSTALL FRONT SUSPENSION MEMBER REAR BRACE RH
Tech Tips
Perform the same procedure as for the LH side.
INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH
INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH
INSTALL FRONT ENGINE MOUNTING BRACKET LOWER REINFORCEMENT (w/ Reinforcement)
INSTALL REAR ENGINE MOUNTING INSULATOR
Fully install the rear engine mounting insulator with the bolt.
INSTALL FRONT ENGINE MOUNTING INSULATOR
Fully install the front engine mounting insulator with the nut and bolt.
Tech Tips
Tighten the through bolt while holding the nut.
INSTALL FRONT DRIVE SHAFT ASSEMBLY
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 TRANSMISSION CONTROL CABLE ASSEMBLY
INSTALL AIR CLEANER BRACKET
Install the air cleaner bracket with the 3 bolts.
INSTALL GLOW PLUG RELAY ASSEMBLY
Install the glow plug relay assembly to the fuel filter support with the bolt.
Connect the wire harness clamp to the fuel filter support.
INSTALL FUEL FILTER SUPPORT
Install the fuel filter support with the 3 bolts.
Attach the clamp to connect the wire harness.
Attach the 2 clamps and connect the engine wire.
Connect the connector.
Connect the ECM connector and lower the lever.
Note
When connecting the ECM connector, make sure that dirt, water or other foreign matter is not stuck between the ECM connector and ECM.
Make sure that the lever is securely locked.
INSTALL FUEL FILTER ASSEMBLY
CONNECT ENGINE WIRE
Connect the ground cable with the bolt.
Connect the 2 connectors and engine wire, attach the 2 claws to the No. 1 engine room relay block and install the 2 nuts.
Install the No. 1 engine room relay block cover.
CONNECT OUTLET HEATER WATER HOSE
Connect the outlet heater water hose to the No. 1 air tube assembly, and slide the clamp to secure the hose.
CONNECT WATER HOSE SUB-ASSEMBLY
Connect the water hose sub-assembly to the No. 1 air tube assembly, and slide the clamp to secure the hose.
CONNECT FUEL HOSE
Connect the fuel hose to the fuel feed pipe sub-assembly.
CONNECT NO. 2 FUEL HOSE
Connect the No. 2 fuel hose to the fuel feed pipe sub-assembly.
CONNECT VACUUM HOSE
Connect the vacuum hose to the No. 2 vacuum hose assembly, and slide the clamp to secure the hose.
INSTALL RADIATOR HOSE SUB-ASSEMBLY
Install the radiator hose sub-assembly to the water outlet.
Connect the radiator hose sub-assembly, and slide the clamp to secure the clamp hose.
INSTALL WATER BY-PASS HOSE ASSEMBLY
Connect the water by-pass hose assembly to the water by-pass pipe.
Connect the water by-pass hose assembly to the No. 1 air tube assembly, and slide the clamp to secure the hose.
INSTALL RADIATOR RESERVE TANK ASSEMBLY
Install the radiator reserve tank assembly with the 2 bolts.
Connect the No. 2 water by-pass hose assembly to the radiator reserve tank assembly, and slide the clamp to secure the hose.
Connect the water by-pass hose assembly to the radiator reserve tank assembly, and slide the clamp to secure the hose.
INSTALL AIR CLEANER CASE SUB-ASSEMBLY
INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY
CONNECT DISCHARGE HOSE SUB-ASSEMBLY (w/ Air Conditioning System)
CONNECT SUCTION HOSE SUB-ASSEMBLY (w/ Air Conditioning System)
INSTALL BATTERY CARRIER
Install the battery carrier with the 4 bolts.
Engage the 2 clamps.
INSTALL BATTERY
Install the battery and battery tray.
Install the battery.
Install the battery insulator to the battery.
Install the battery clamp sub-assembly with the battery clamp bolt, bolt and nut.
Connect the cable to the positive (+) battery terminal and tighten the nut.
INSTALL FRONT LOWER BUMPER ABSORBER
Install the 2 hooks of the front lower bumper absorber into the installation holes in the body to install the front lower bumper absorber.
Install the front lower bumper absorber with the 4 bolts.
INSTALL RADIATOR ASSEMBLY
INSTALL FRONT EXHAUST PIPE ASSEMBLY
INSTALL FRONT CENTER FLOOR BRACE SUB-ASSEMBLY
ADD MANUAL TRANSAXLE OIL
ADD ENGINE OIL
INSTALL OUTER COWL TOP PANEL
for LHD:
for RHD
INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY
PERFORM REGISTRATION
INSPECT FOR ENGINE OIL LEAK
INSPECT FOR FUEL LEAK
INSPECT FOR EXHAUST GAS LEAK
INSTALL REAR ENGINE UNDER COVER RH
Install the rear engine under cover RH with the 5 clips.
INSTALL REAR ENGINE UNDER COVER LH
Install the rear engine under cover LH with the 5 clips.
INSTALL NO. 2 ENGINE UNDER COVER
Install the No. 2 engine under cover with the 4 clips.
INSTALL CENTER NO. 4 ENGINE UNDER COVER (w/ Cover)
Install the center No. 4 engine under cover with the 2 clips.
INSTALL NO. 1 ENGINE COVER
*a | Installation Points |
Attach the 4 clips in the sequence shown in the illustration to install the No. 1 engine cover.
Tech Tips
When attaching the clips, press the protrusions on the top of the No. 1 engine cover at the clip installation points.
INSPECT ENGINE IDLE SPEED
INSPECT MAXIMUM ENGINE SPEED
INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
CHECK SPEED SENSOR SIGNAL