CAUTION / NOTICE / HINT
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.
Tech Tips
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 Click here.
PROCEDURE
INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY LH
Tech Tips
Perform this procedure only when replacement of the engine mounting insulator is necessary.
Install the engine mounting insulator with the 4 bolts.
INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH
Tech Tips
Perform this procedure only when replacement of the engine mounting insulator is necessary.
Install the engine mounting insulator with the 3 bolts.
Install the 2 cooler pipe brackets with the 2 bolts and nut.
Connect the cooler pipe clamp.
INSTALL REAR ENGINE MOUNTING INSULATOR
Tech Tips
Perform this procedure only when replacement of the engine mounting insulator is necessary.
Install the engine mounting insulator with the 2 bolts and 2 nuts.
INSTALL FRONT ENGINE MOUNTING INSULATOR
Tech Tips
Perform this procedure only when replacement of the engine mounting insulator is necessary.
Install the engine mounting insulator with the 2 bolts.
INSTALL ENGINE HANGER
REMOVE ENGINE STAND
Attach a sling device and hang the engine with a chain block.
Lift the engine and remove it from the engine stand.
INSTALL ENGINE WIRE
Install the engine wire to the engine.
INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY (for Manual Transaxle)
clutch release with bearing cylinder assembly Click here.
INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for CVT)
INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)
INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)
INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)
INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transaxle)
INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY
Install the continuously variable transaxle assembly Click here.
INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)
Install the manual transaxle assembly Click here.
INSTALL FLYWHEEL HOUSING SIDE COVER
INSTALL STARTER ASSEMBLY
TEMPORARILY INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
Temporarily install the rear engine mounting insulator to the engine mounting bracket with the through bolt.
INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
Place the engine on an engine lifter.
Tech Tips
Place the engine on wooden blocks or equivalent so that the engine is level.
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.
Temporarily install the front suspension crossmember with 2 new bolts.
Temporarily install the member brace rear RH and LH with 2 new bolts and the 4 bolts.
New Bolt | |
Bolt |
Install the engine mounting insulator LH with the through bolt and nut.
Install the engine mounting insulator RH with the bolt and 2 nuts.
Tighten the 2 front suspension member bolts.
Tighten the 6 member brace rear bolts.
Remove the 2 bolts and 2 engine hangers.
Install the air fuel ratio sensor bracket with the bolt. Then connect the air fuel ratio sensor connector.
INSTALL FRONT CROSSMEMBER SUB-ASSEMBLY
Temporarily install the front crossmember with the 4 bolts.
Temporarily install the front engine mounting insulator to the front engine mounting bracket with the bolt and nut.
Tighten the 4 front crossmember bolts.
Tighten the front engine mounting insulator bolt and nut.
TIGHTEN FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
Tighten the rear engine mounting insulator bolt.
INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH
Install the reinforcement with the 4 bolts.
Note
Tighten the bolts in the order of C, B, D and A.
INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH
Install the reinforcement with the 4 bolts.
Note
Tighten the bolts in the order of C, B, D and A.
INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT (for CVT)
INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
INSTALL FRONT AXLE ASSEMBLY LH
Install the front axle assembly LH Click here.
INSTALL FRONT AXLE ASSEMBLY RH
Tech Tips
Use the same procedures described for the LH side.
CONNECT FRONT STABILIZER LINK ASSEMBLY LH
CONNECT FRONT STABILIZER LINK ASSEMBLY RH
Tech Tips
Use the same procedures described for the LH side.
INSTALL FRONT AXLE SHAFT NUT LH
INSTALL FRONT AXLE SHAFT NUT RH
Tech Tips
Use the same procedures described for the LH side.
INSTALL FRONT EXHAUST PIPE ASSEMBLY
INSTALL FRONT CENTER FLOOR BRACE
CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY
CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY
INSTALL COLUMN HOLE COVER SILENCER SHEET
CONNECT WIRE HARNESS AND HOSE
Connect the vacuum hose.
Connect the connector tube hose.
Connect the engine wire with the bolt.
Connect the engine wire with the 2 bolt and clamp.
Connect the connector to the battery current sensor.
Attach the 2 clamps to install the wire harness, and then install the 2 nuts.
Connect the 3 wire harness connectors to the engine room No. 1 junction block.
Connect the ECM connector and lower the lever.
Note
When connecting the connector, make sure that dirt, water or other foreign matter does not get caught between the connector and other parts.
Make sure that the lever is securely lowered.
Connect the wire harness clamp.
CONNECT HEATER WATER HOSE
Connect the 2 heater water hoses.
CONNECT FUEL TUBE SUB-ASSEMBLY
Connect the fuel tube connector and fuel pipe.
Note
Align the fuel tube connector with the pipe, and then push the fuel tube connector on until the retainer makes a "click" sound. If the connection is tight, apply a small amount of engine oil to the tip of the pipe. After connecting the connector, pull the pipe and connector to make sure that they are securely connected.
Attach the claw to install the No. 1 fuel pipe clamp.
CONNECT NO. 1 RADIATOR HOSE
*1 | Top |
Connect the radiator hose to the cylinder head.
Tech Tips
The direction of the hose clamp is indicated in the illustration.
for CVT:
Connect the No. 1 breather plug to the clamp.
CONNECT CLUTCH HOSE (for Manual Transaxle)
Connect the clutch hose and install the clip to the clutch hose.
Note
Install the clip as far as it will go.
Using a 10 mm union nut wrench, connect the clutch hose to the flexible hose tube while holding the clutch hose.
Note
Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.
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.
CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)
Connect the control cable assembly with the nut.
Connect the 2 transmission control cables with 2 new clips.
Install the 2 clips.
CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for CVT)
Connect the transmission control cable support with the bolt.
Connect the transmission control cable to the bracket with a new clip.
Connect the transmission control cable to the control shaft lever with the nut.
INSTALL BATTERY CARRIER
Install the battery carrier with the 4 bolts.
Install the radiator pipe with the 2 bolts.
Connect the 2 wire harness clamps.
INSTALL BATTERY TRAY
INSTALL BATTERY
INSTALL BATTERY CLAMP SUB-ASSEMBLY
Install the battery clamp with the bolt and nut.
Connect the cable to the positive (+) battery terminal.
INSTALL AIR CLEANER CASE SUB-ASSEMBLY
INSTALL AIR CLEANER CAP SUB-ASSEMBLY
CONNECT COMPRESSOR WITH PULLEY ASSEMBLY (w/ Air Conditioning System)
Using an E8 "TORX" socket wrench, connect the compressor assembly with pulley with the 2 stud bolts.
Install the 2 bolts and 2 nuts.
Tech Tips
Tighten the bolts and the nuts in the order shown in the illustration.
Connect the connector.
CONNECT NO. 2 RADIATOR HOSE
*1 | Top |
Connect the radiator hose to the water inlet.
Tech Tips
The direction of the hose clamp is indicated in the illustration.
INSTALL GENERATOR ASSEMBLY
INSTALL V-RIBBED BELT
CONNECT RADIATOR RESERVOIR ASSEMBLY
Install the grommet to the radiator reservoir.
Connect the radiator reservoir with the 2 bolts.
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Note
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
ADD MANUAL TRANSAXLE OIL
INSPECT MANUAL TRANSAXLE OIL
ADD CONTINUOUSLY VARIABLE TRANSAXLE FLUID
Add continuously variable transaxle fluid Click here.
ADD ENGINE COOLANT
ADD ENGINE OIL
INSPECT FOR FUEL LEAK
INSPECT FOR COOLANT LEAK
INSPECT FOR OIL LEAK
INSPECT FOR EXHAUST GAS LEAK
INSPECT V-RIBBED BELT
INSPECT IGNITION TIMING
INSPECT ENGINE IDLE SPEED
INSPECT CO/HC
ADJUST FRONT WHEEL ALIGNMENT
Adjust the front wheel alignment Click here.
PERFORM CLUTCH ENGAGEMENT POINT LEARNING (for Manual Transaxle)
INSTALL NO. 2 ENGINE UNDER COVER
Install the under cover with the 4 clips.
INSTALL CENTER NO. 4 ENGINE UNDER COVER
Install the under cover with the 2 clips.
INSTALL REAR ENGINE UNDER COVER RH
INSTALL REAR ENGINE UNDER COVER LH
Install the under cover LH with the 5 clips.
INSTALL NO. 1 ENGINE UNDER COVER
Install the under cover with the 11 clips.
INSTALL FRONT LOWER BUMPER ABSORBER
Install the front lower bumper absorber with the 3 screws and 8 bolts.
Install the 4 screws and 2 bolts.
INSTALL RADIATOR SUPPORT OPENING COVER
INSTALL NO. 2 CYLINDER HEAD COVER