ENGINE ASSEMBLY INSTALLATION

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

  1. 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 to the vehicle body with the 4 bolts.

      95 N*m

      969 kgf*cm

      70 ft.*lbf

  2. TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR

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

  3. TEMPORARILY INSTALL REAR ENGINE MOUNTING INSULATOR

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

  4. 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.

    1. Install a sling device and chain block to the engine assembly and hang the engine assembly.

    2. Remove the engine assembly from the engine stand.

  5. INSTALL MANUAL TRANSAXLE ASSEMBLY

    1. C208259

      Make sure that the dowel pins are not loose, bent, damaged or scratched.

    2. Align the input shaft with the clutch disc assembly and install the engine assembly to the transaxle.

    3. C330944

      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.

  6. TEMPORARILY INSTALL NO. 2 MANIFOLD STAY

    Click here

  7. TEMPORARILY INSTALL STARTER ASSEMBLY

    Click here

  8. TIGHTEN ENGINE AND TRANSAXLE CONNECTING BOLT

    Click here

  9. INSTALL NO. 1 CLUTCH HOUSING COVER

    Click here

  10. INSTALL NO. 1 AIR TUBE ASSEMBLY

    1. Install the No. 1 air tube assembly to the manual transaxle assembly with the 2 bolts.

      20 N*m

      204 kgf*cm

      15 ft.*lbf

    2. Connect the No. 4 water by-pass hose to the EGR cooler assembly.

    3. Connect the compressor outlet elbow to the turbocharger sub-assembly.

  11. INSTALL ENGINE WIRE

    1. Connect the connectors, attach the clamps and install the engine wire to the engine assembly with the bracket bolts.

  12. 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 bolt and nut.

      56 N*m

      571 kgf*cm

      41 ft.*lbf

      Tip:

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

    4. A318551N01

      Install the engine mounting insulator sub-assembly RH with the 4 bolts and 3 nuts.

      Bolt and Nut (A)

      95 N*m

      969 kgf*cm

      70 ft.*lbf

      Nut (B)

      52 N*m

      530 kgf*cm

      38 ft.*lbf

    5. Attach the 2 clamps and connect the suction pipe sub-assembly.

    6. Attach the clamp and connect the air conditioner tube and accessory assembly.

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

      99 N*m

      1010 kgf*cm

      73 ft.*lbf

    8. 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

  13. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

  14. INSTALL FRONT SUSPENSION MEMBER REAR BRACE LH

    Click here

  15. INSTALL FRONT SUSPENSION MEMBER REAR BRACE RH

    Tip:

    Perform the same procedure as for the LH side.

  16. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH

    Click here

  17. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Click here

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

    Click here

  19. INSTALL REAR ENGINE MOUNTING INSULATOR

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

      95 N*m

      969 kgf*cm

      70 ft.*lbf

  20. INSTALL FRONT ENGINE MOUNTING INSULATOR

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

      145 N*m

      1479 kgf*cm

      107 ft.*lbf

      Tip:

      Tighten the through bolt while holding the nut.

  21. INSTALL FRONT DRIVE SHAFT ASSEMBLY

    Click here

  22. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  23. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  24. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  25. CONNECT CLUTCH RELEASE CYLINDER ASSEMBLY

    Click here

  26. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    Click here

  27. INSTALL AIR CLEANER BRACKET

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

      7.0 N*m

      71 kgf*cm

      62 in.*lbf

  28. INSTALL GLOW PLUG RELAY ASSEMBLY

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

      17.5 N*m

      178 kgf*cm

      13 ft.*lbf

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

  29. 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. Attach the clamp to connect the wire harness.

    3. Attach the 2 clamps and connect the engine wire.

    4. Connect the connector.

    5. A318487

      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.

  30. INSTALL FUEL FILTER ASSEMBLY

    Click here

  31. CONNECT ENGINE WIRE

    1. Connect the ground cable with the bolt.

      12.5 N*m

      127 kgf*cm

      9 ft.*lbf

    2. Connect the 2 connectors and engine wire, attach the 2 claws to the No. 1 engine room relay block and install the 2 nuts.

      8.4 N*m

      86 kgf*cm

      74 in.*lbf

    3. Install the No. 1 engine room relay block cover.

  32. CONNECT OUTLET HEATER WATER HOSE

    1. Connect the outlet heater water hose to the No. 1 air tube assembly, and slide the clamp to secure the hose.

  33. CONNECT WATER HOSE SUB-ASSEMBLY

    1. Connect the water hose sub-assembly to the No. 1 air tube assembly, and slide the clamp to secure the hose.

  34. CONNECT FUEL HOSE

    1. Connect the fuel hose to the fuel feed pipe sub-assembly.

  35. CONNECT NO. 2 FUEL HOSE

    1. Connect the No. 2 fuel hose to the fuel feed pipe sub-assembly.

  36. CONNECT VACUUM HOSE

    1. Connect the vacuum hose to the No. 2 vacuum hose assembly, and slide the clamp to secure the hose.

  37. INSTALL RADIATOR HOSE SUB-ASSEMBLY

    1. Install the radiator hose sub-assembly to the water outlet.

    2. Connect the radiator hose sub-assembly, and slide the clamp to secure the clamp hose.

  38. INSTALL WATER BY-PASS HOSE ASSEMBLY

    1. Connect the water by-pass hose assembly to the water by-pass pipe.

    2. Connect the water by-pass hose assembly to the No. 1 air tube assembly, and slide the clamp to secure the hose.

  39. INSTALL RADIATOR RESERVE TANK ASSEMBLY

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

      5.0 N*m

      51 kgf*cm

      44 in.*lbf

    2. Connect the No. 2 water by-pass hose assembly to the radiator reserve tank assembly, and slide the clamp to secure the hose.

    3. Connect the water by-pass hose assembly to the radiator reserve tank assembly, and slide the clamp to secure the hose.

  40. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  41. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY

    Click here

  42. CONNECT DISCHARGE HOSE SUB-ASSEMBLY (w/ Air Conditioning System)

    Click here

  43. CONNECT SUCTION HOSE SUB-ASSEMBLY (w/ Air Conditioning System)

    Click here

  44. INSTALL BATTERY CARRIER

    1. Install the battery carrier with the 4 bolts.

      18.5 N*m

      189 kgf*cm

      14 ft.*lbf

    2. Engage the 2 clamps.

  45. INSTALL BATTERY

    1. Install the battery and battery tray.

    2. Install the battery.

    3. Install the battery insulator to the battery.

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

      Nut

      3.5 N*m

      36 kgf*cm

      31 in.*lbf

      Bolt

      16.5 N*m

      168 kgf*cm

      12 ft.*lbf

    5. Connect the cable to the positive (+) battery terminal and tighten the nut.

      5.4 N*m

      55 kgf*cm

      48 in.*lbf

  46. INSTALL FRONT LOWER BUMPER ABSORBER

    1. Install the 2 hooks of the front lower bumper absorber into the installation holes in the body to install the front lower bumper absorber.

    2. Install the front lower bumper absorber with the 4 bolts.

  47. INSTALL RADIATOR ASSEMBLY

    Click here

  48. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  49. INSTALL FRONT CENTER FLOOR BRACE SUB-ASSEMBLY

    Click here

  50. ADD MANUAL TRANSAXLE OIL

    Click here

  51. ADD ENGINE OIL

    Click here

  52. INSTALL OUTER COWL TOP PANEL

  53. INSTALL WINDSHIELD WIPER MOTOR ASSEMBLY

    Click here

  54. PERFORM REGISTRATION

    Click here

  55. INSPECT FOR ENGINE OIL LEAK

    Click here

  56. INSPECT FOR FUEL LEAK

    Click here

  57. INSPECT FOR EXHAUST GAS LEAK

    Click here

  58. INSTALL REAR ENGINE UNDER COVER RH

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

  59. INSTALL REAR ENGINE UNDER COVER LH

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

  60. INSTALL NO. 2 ENGINE UNDER COVER

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

  61. INSTALL CENTER NO. 4 ENGINE UNDER COVER (w/ Cover)

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

  62. INSTALL NO. 1 ENGINE COVER

    1. A316692C01

      *a

      Installation Points

      Attach the 4 clips in the sequence shown in the illustration to install the No. 1 engine cover.

      Tip:

      When attaching the clips, press the protrusions on the top of the No. 1 engine cover at the clip installation points.

  63. INSPECT ENGINE IDLE SPEED

    Click here

  64. INSPECT MAXIMUM ENGINE SPEED

    Click here

  65. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  66. CHECK SPEED SENSOR SIGNAL

    Click here