PROCEDURE
REMOVE ENGINE FROM ENGINE STAND
*1 | No. 1 Engine Hanger |
*2 | No. 2 Engine Hanger |
Install the No. 1 and No. 2 engine hangers with 2 bolts as shown in the illustration.
Tech Tips
No. 1 engine hanger | 12281-26040 |
No. 2 engine hanger | 12282-26010 |
Bolt | 91552-81025 or 90105-W0042 |
Insert the claw of the No. 1 engine hanger into the hole of the cylinder head.
Fit the fork part of the No. 2 engine hanger onto the rib of the cylinder head.
Install a sling device and chain block to the engine and hang the engine.
Remove the engine from the engine stand.
INSTALL FLYWHEEL SUB-ASSEMBLY
Hold the crankshaft pulley with SST.
Using a T55 "TORX" socket wrench, install 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 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
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 INSULATOR RH
Tech Tips
Perform this procedure only when replacement of the engine mounting insulator is necessary.
Install the engine mounting insulator RH with the 3 bolts.
INSTALL ENGINE MOUNTING INSULATOR LH
Tech Tips
Perform this procedure only when replacement of the engine mounting insulator is necessary.
Install the engine mounting insulator LH with the 4 bolts.
INSTALL ENGINE MOUNTING BRACKET LH
Tech Tips
Perform this procedure only when replacement of the engine mounting bracket is necessary.
Install the engine mounting bracket LH with the 4 bolts.
INSTALL REAR ENGINE MOUNTING BRACKET
Install the rear engine mounting bracket with the 5 bolts.
INSTALL FRONT ENGINE MOUNTING BRACKET
Install the front engine mounting bracket with the 3 bolts.
INSTALL ENGINE WIRE
INSTALL STARTER ASSEMBLY (for VALEO Made)
INSTALL STARTER ASSEMBLY (for DENSO Made)
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 tube and hose.
INSTALL REAR ENGINE MOUNTING INSULATOR
Install the rear engine mounting insulator with the 3 bolts and 2 nuts.
INSTALL ENGINE 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.
Using the chain block, slowly install the engine to the vehicle and the intermediate shaft to the pinion.
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 suspension crossmember with 2 new bolts.
New Bolt | |
Bolt |
Temporarily install the rear brace RH and LH with 2 new bolts and the 4 bolts.
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 RH with the 2 bolts and 2 nuts.
Tighten the 8 bolts.
Remove the 2 bolts, No. 1 and No. 2 engine hangers.
Attach the 3 clamps and connect the wire harness.
Connect the cable bracket with the bolt.
INSTALL FRONT ENGINE MOUNTING INSULATOR
*1 | Through Bolt |
*2 | Nut |
Install the front engine mounting insulator with through bolt and nut.
INSTALL FRONT CROSSMEMBER SUB-ASSEMBLY
Install the front crossmember with the 6 bolts.
INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH
Install the front suspension member reinforcement LH with the 4 bolts.
Note
Tighten the bolts in the order shown in the illustration.
INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
INSTALL FRONT AXLE ASSEMBLY LH
INSTALL FRONT AXLE ASSEMBLY RH
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 and flexible hose bracket with the 6 bolts.
CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
Connect the transmission control cable to the control cable bracket with 2 new clips.
Install the 2 pins.
CONNECT COMPRESSOR WITH PULLEY ASSEMBLY (w/ Air Conditioning System)
Using an E8 "TORX" socket wrench, connect the compressor with the 2 stud bolts.
*1 | Nut |
Install the 2 bolts and 2 nuts.
Connect the connector.
INSTALL FAN AND GENERATOR V BELT
INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH
INSTALL INJECTOR DRIVER
Install the injector driver with the 3 screws.
Attach the clamp and connect the 4 connectors.
CONNECT NO. 2 RADIATOR HOSE
Connect the No. 2 radiator hose.
CONNECT WATER BY-PASS HOSE
Connect the water by-pass hose.
INSTALL INTERCOOLER AIR HOSE
CONNECT NO. 1 RADIATOR HOSE
Connect the No. 1 radiator hose.
CONNECT INLET HEATER WATER HOSE
Connect the inlet heater water hose.
CONNECT OUTLET HEATER WATER HOSE
Connect the outlet heater water hose
CONNECT HOSES AND CONNECTORS
Connect the vacuum pump hose.
Connect the 2 fuel hoses.
Connect the ECM connector and lower the lever.
Note
When connecting the connector, make sure that dirt, water and other foreign matter is not stuck between the connector and ECM.
Make sure that the lever is securely lowered.
Attach the 4 clamps and connect the wire harness.
Install the air cleaner bracket with the 5 bolts.
for LHD:
Attach the 5 clamps and connect the 2 connectors.
for RHD:
Attach the 3 clamps and connect the 2 connectors.
Connect the ground cable with the bolt.
Connect the 3 connectors, attach the 2 claws to install the No. 1 engine room relay block and install the 2 nuts.
Connect the current sensor connector.
Install the engine room No. 1 relay block cover.
INSTALL FUEL FILTER ASSEMBLY (w/o Combustion Type Power Heater)
INSTALL FUEL FILTER ASSEMBLY (w/ Combustion Type Power Heater)
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
Connect the air cleaner hose.
Attach the 4 clamps to install the air cleaner cap.
Connect the No. 2 ventilation hose.
Connect the mass air flow meter connector.
INSTALL NO. 3 AIR HOSE
CONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY
Connect the No. 2 vacuum transmitting hose to the intake manifold.
INSTALL BATTERY CARRIER
INSTALL BATTERY TRAY
INSTALL BATTERY
INSTALL BATTERY INSULATOR
INSTALL BATTERY CLAMP SUB-ASSEMBLY
INSTALL DIFFERENTIAL PRESSURE SENSOR ASSEMBLY
INSTALL FRONT EXHAUST PIPE ASSEMBLY
ADD MANUAL TRANSAXLE OIL
INSPECT FOR MANUAL TRANSAXLE OIL LEAK
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 Click here.
ADD ENGINE COOLANT
BLEED FUEL SYSTEM
PERFORM REGISTRATION
Perform registration of the injector compensation codes.
w/ Gear Shift Indicator: Click here
w/o Gear Shift Indicator: Click here
Perform registration of the pilot quantity learning.
w/ Gear Shift Indicator: Click here
w/o Gear Shift Indicator: Click here
PERFORM INITIALIZATION
Perform initialization of the crank time compensation reset function.
w/ Gear Shift Indicator: Click here
w/o Gear Shift Indicator: Click here
PERFORM THROTTLE VALVE FULLY CLOSED POSITION LEARNING
INSPECT FOR OIL LEAK
INSPECT FOR COOLANT LEAK
INSPECT FOR FUEL LEAK
INSPECT FOR EXHAUST GAS LEAK
INSTALL REAR ENGINE UNDER COVER RH
INSTALL REAR ENGINE UNDER COVER LH
Install the rear engine under cover LH with the 5 clips.
INSTALL NO. 2 ENGINE UNDER COVER
INSTALL CENTER NO. 4 ENGINE UNDER COVER
Install the center No. 4 engine under cover with the 2 clips.
INSTALL NO. 1 ENGINE UNDER COVER
INSTALL FRONT LOWER BUMPER ABSORBER
INSTALL NO. 1 ENGINE COVER
INSTALL RADIATOR SUPPORT OPENING COVER
INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY
Install the outer cowl top panel with the 9 bolts.
Attach the clamp and connect the connector.
INSTALL FRONT WIPER MOTOR AND LINK ASSEMBLY
INSTALL FRONT WHEEL
CHECK IDLE SPEED
CHECK MAXIMUM ENGINE SPEED
ADJUST FRONT WHEEL ALIGNMENT
CHECK ABS SPEED SENSOR SIGNAL
PERFORM CLUTCH ENGAGEMENT POINT LEARNING