ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:

The engine assembly with transaxle is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop.

PROCEDURE

  1. INSTALL ENGINE HANGER

  2. REMOVE ENGINE FROM ENGINE STAND

    1. Remove the engine assembly from the engine stand.

  3. INSTALL ENGINE MOUNTING INSULATOR LH

    A327671E01
    Tip:

    Perform this procedure only when replacement of the engine mounting insulator LH is necessary.

    1. Temporarily install the engine mounting insulator LH with the 3 bolts.

    2. Fully tighten the 3 bolts in the order shown in the illustration.

      52 N*m

      530 kgf*cm

      38 ft.*lbf

  4. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    A327660E01
    Tip:

    Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.

    1. Temporarily install the engine mounting insulator sub-assembly RH with the 3 bolts.

    2. Fully tighten the 3 bolts in the order shown in the illustration.

      30 N*m

      306 kgf*cm

      22 ft.*lbf

  5. INSTALL CLUTCH DISC ASSEMBLY

  6. INSTALL CLUTCH COVER ASSEMBLY

  7. INSTALL ENGINE ASSEMBLY

    1. A327237C02
      V100135

      Bolt

      V100136

      Nut

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

    2. Install the 5 bolts and 2 nuts.

      Bolt

      55 N*m

      561 kgf*cm

      41 ft.*lbf

      Nut

      55 N*m

      561 kgf*cm

      41 ft.*lbf

      Note:

      Insert knock pins into the knock pin holes securely so that the end face of the transaxle fits close against the engine before tightening the bolts.

  8. INSTALL STARTER ASSEMBLY

  9. INSTALL ENGINE WIRE

    1. Install the engine wire to the engine assembly.

  10. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    1. Set the engine assembly with transaxle on an engine lifter.

      Note:
      • Using height adjustment attachments and plate lift attachments, place the engine assembly with transaxle horizontally.

    2. Operate the engine lifter and lift the engine assembly with transaxle to the position where the engine mounting insulator sub-assembly RH and engine mounting insulator LH can be installed.

      CAUTION:

      Do not raise the engine assembly with transaxle more than necessary. If the engine assembly with transaxle is raised excessively, the vehicle may also be lifted up.

      Note:
      • Make sure that the engine assembly with transaxle is clear of all wiring and hoses.

      • While raising the engine assembly with transaxle into the vehicle, do not allow it to contact the vehicle.

    3. A327670E01

      Temporarily install the engine mounting insulator LH with the 3 bolts.

    4. Fully tighten the 3 bolts in the order shown in the illustration.

      52 N*m

      530 kgf*cm

      38 ft.*lbf

    5. Install the engine mounting insulator sub-assembly RH with the 3 nuts.

      30 N*m

      306 kgf*cm

      22 ft.*lbf

    6. By inserting SST into the datum holes in the front suspension crossmember RH and LH alternately, tighten the bolts (A), (B) and (C) on both sides to the specified torque in several steps.

      A322521C01

      *a

      Datum Hole

      *b

      Correct

      *c

      Incorrect

      -

      -

      V100135

      Front of the Vehicle

      -

      -

      09670-00011

      Bolt (A)

      85 N*m

      867 kgf*cm

      63 ft.*lbf

      Bolt (B)

      134 N*m

      1366 kgf*cm

      99 ft.*lbf

      Bolt (C)

      48 N*m

      489 kgf*cm

      35 ft.*lbf

      Note:
      • Insert SST into the datum hole vertically.

      • If impossible to insert SST vertically, loosen all bolts and then insert SST again.

    7. Lower the engine lifter.

  11. REMOVE ENGINE HANGER

  12. INSTALL FRONT EXHAUST PIPE ASSEMBLY

  13. INSTALL FRONT DRIVE SHAFT ASSEMBLY

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

  15. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

  16. INSTALL STEERING COLUMN HOLE COVER PLATE

  17. CONNECT CLUTCH RELEASE CABLE ASSEMBLY

  18. INSPECT AND ADJUST CLUTCH PEDAL HEIGHT

    for LHD:Click here

    for RHD:Click here

  19. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

  20. INSTALL INTAKE MANIFOLD

  21. CONNECT ENGINE WIRE

    1. Connect the No. 3 engine wire to the vehicle body with bolt.

      8.4 N*m

      86 kgf*cm

      74 in.*lbf

    2. Engage the 2 claws and connect the wire harness to the No. 1 engine room relay block.

    3. Install the nut.

      8.4 N*m

      86 kgf*cm

      74 in.*lbf

    4. Connect the 2 connectors to the No. 1 engine room relay block.

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

    6. A327466

      Connect the ECM connector and lower the lever.

      Note:
      • When connecting the ECM connector, make sure that dirt, water or other foreign matter does not contact the connecting parts of the ECM connector.

      • Be sure to securely connect the ECM connector.

  22. INSTALL RADIATOR RESERVE TANK ASSEMBLY

    1. Connect the No. 5 water by-pass hose from the No. 1 water by-pass pipe.

    2. Connect the No. 5 water by-pass hose from the radiator reserve tank assembly.

    3. Connect the water by-pass hose from the radiator reserve tank assembly.

    4. C302793C01

      *a

      Grommet

      Install the radiator reserve tank assembly and engage the guide and grommet as shown in the illustration.

    5. Install the bolt to secure the radiator reserve tank assembly.

      7.5 N*m

      76 kgf*cm

      66 in.*lbf

  23. CONNECT NO. 1 RADIATOR HOSE

  24. CONNECT INLET HEATER WATER HOSE

  25. CONNECT OUTLET HEATER WATER HOSE

  26. INSTALL WITH MAGNET CLUTCH COMPRESSOR (w/ Air Conditioning System)

    1. Temporarily install the compressor assembly with pulley with the 3 bolts.

    2. Fully tighten the 3 bolts.

      25 N*m

      255 kgf*cm

      18 ft.*lbf

    3. Connect the connector.

  27. INSTALL GENERATOR ASSEMBLY

  28. INSTALL FAN AND GENERATOR V BELT

  29. INSPECT FAN AND GENERATOR V BELT

  30. INSTALL BATTERY CLAMP SUB-ASSEMBLY

    1. A322358N01

      Engage the claw and install the battery clamp sub-assembly to the No. 1 engine room relay block.

    2. Install the battery clamp sub-assembly with the 5 bolts in the order shown in the illustration.

      Bolt (A)

      8.4 N*m

      86 kgf*cm

      74 in.*lbf

      Bolt (B)

      7.4 N*m

      75 kgf*cm

      65 in.*lbf

      Bolt (C)

      17.2 N*m

      175 kgf*cm

      13 ft.*lbf

    3. Engage the 5 wire harness clamps and connect the wire harness to the battery clamp sub-assembly.

  31. INSTALL BATTERY

    1. Install the battery to the battery clamp sub-assembly.

    2. Install the No.2 battery clamp to the battery clamp sub-assembly with the bolt.

      15.1 N*m

      154 kgf*cm

      11 ft.*lbf

    3. Engage the 2 claws to connect the engine room main wire to the engine wire.

    4. Install the engine room main wire with engine wire to the positive (+) battery terminal with the nut.

      7.6 N*m

      77 kgf*cm

      67 in.*lbf

  32. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

  33. INSTALL OUTER COWL TOP PANEL

    for LHD:Click here

    for RHD:Click here

  34. INSTALL FRONT AIR SHUTTER SEAL RH

    for LHD:Click here

    for RHD:Click here

  35. INSTALL FRONT NO. 1 VENTILATOR SEAL

    for LHD:Click here

    for RHD:Click here

  36. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

  37. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    1. Connect the cable to the negative (-) battery terminal.

      5.4 N*m

      55 kgf*cm

      48 in.*lbf

      Note:

      When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

      Click hereClick here

  38. ADD ENGINE OIL

  39. ADD ENGINE COOLANT

  40. ADD MANUAL TRANSAXLE OIL

  41. CHECK ENGINE OIL LEVEL

  42. INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY

    for LHD:Click here

    for RHD:Click here

  43. INSPECT FOR FUEL LEAK

  44. INSPECT FOR COOLANT LEAK

  45. INSPECT FOR OIL LEAK

  46. INSPECT FOR EXHAUST GAS LEAK

  47. INSTALL FRONT WHEELS

  48. ADJUST FRONT WHEEL ALIGNMENT

  49. CHECK SPEED SENSOR SIGNAL

    w/o VSC:Click here

    w/ VSC:Click here