ENGINE ASSEMBLY INSTALLATION
CAUTION / NOTICE / HINT
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
INSTALL ENGINE HANGER
REMOVE ENGINE FROM ENGINE STAND
Remove the engine assembly from the engine stand.
INSTALL ENGINE MOUNTING INSULATOR LH
Tip:Perform this procedure only when replacement of the engine mounting insulator LH is necessary.
Temporarily install the engine mounting insulator LH with the 3 bolts.
Fully tighten the 3 bolts in the order shown in the illustration.
52 N*m
530 kgf*cm
38 ft.*lbf
INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH
Tip:Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.
Temporarily install the engine mounting insulator sub-assembly RH with the 3 bolts.
Fully tighten the 3 bolts in the order shown in the illustration.
30 N*m
306 kgf*cm
22 ft.*lbf
INSTALL CLUTCH DISC ASSEMBLY
INSTALL CLUTCH COVER ASSEMBLY
INSTALL ENGINE ASSEMBLY
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Bolt
Nut
Align the input shaft with the clutch disc assembly and install the engine assembly to the manual transaxle.
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.
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INSTALL STARTER ASSEMBLY
INSTALL ENGINE WIRE
Install the engine wire to the engine assembly.
INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
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.
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.
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Temporarily install the engine mounting insulator LH with the 3 bolts.
Fully tighten the 3 bolts in the order shown in the illustration.
52 N*m
530 kgf*cm
38 ft.*lbf
Install the engine mounting insulator sub-assembly RH with the 3 nuts.
30 N*m
306 kgf*cm
22 ft.*lbf
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.
*a
Datum Hole
*b
Correct
*c
Incorrect
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Front of the Vehicle
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-
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.
Lower the engine lifter.
REMOVE ENGINE HANGER
INSTALL FRONT EXHAUST PIPE ASSEMBLY
INSTALL FRONT DRIVE SHAFT ASSEMBLY
INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY
INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY
INSTALL STEERING COLUMN HOLE COVER PLATE
CONNECT CLUTCH RELEASE CABLE ASSEMBLY
INSPECT AND ADJUST CLUTCH PEDAL HEIGHT
for LHD:Click here
for RHD:Click here
CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
INSTALL INTAKE MANIFOLD
CONNECT ENGINE WIRE
Connect the No. 3 engine wire to the vehicle body with bolt.
8.4 N*m
86 kgf*cm
74 in.*lbf
Engage the 2 claws and connect the wire harness to the No. 1 engine room relay block.
Install the nut.
8.4 N*m
86 kgf*cm
74 in.*lbf
Connect the 2 connectors to the No. 1 engine room relay block.
Install the No. 1 engine room relay block cover.
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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.
INSTALL RADIATOR RESERVE TANK ASSEMBLY
Connect the No. 5 water by-pass hose from the No. 1 water by-pass pipe.
Connect the No. 5 water by-pass hose from the radiator reserve tank assembly.
Connect the water by-pass hose from the radiator reserve tank assembly.
-
*a
Grommet
Install the radiator reserve tank assembly and engage the guide and grommet as shown in the illustration.
Install the bolt to secure the radiator reserve tank assembly.
7.5 N*m
76 kgf*cm
66 in.*lbf
CONNECT NO. 1 RADIATOR HOSE
CONNECT INLET HEATER WATER HOSE
CONNECT OUTLET HEATER WATER HOSE
INSTALL WITH MAGNET CLUTCH COMPRESSOR (w/ Air Conditioning System)
Temporarily install the compressor assembly with pulley with the 3 bolts.
Fully tighten the 3 bolts.
25 N*m
255 kgf*cm
18 ft.*lbf
Connect the connector.
INSTALL GENERATOR ASSEMBLY
INSTALL FAN AND GENERATOR V BELT
INSPECT FAN AND GENERATOR V BELT
INSTALL BATTERY CLAMP SUB-ASSEMBLY
-
Engage the claw and install the battery clamp sub-assembly to the No. 1 engine room relay block.
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
Engage the 5 wire harness clamps and connect the wire harness to the battery clamp sub-assembly.
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INSTALL BATTERY
Install the battery to the battery clamp sub-assembly.
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
Engage the 2 claws to connect the engine room main wire to the engine wire.
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
INSTALL AIR CLEANER CASE SUB-ASSEMBLY
INSTALL OUTER COWL TOP PANEL
for LHD:Click here
for RHD:Click here
INSTALL FRONT AIR SHUTTER SEAL RH
for LHD:Click here
for RHD:Click here
INSTALL FRONT NO. 1 VENTILATOR SEAL
for LHD:Click here
for RHD:Click here
INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
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.
ADD ENGINE OIL
ADD ENGINE COOLANT
ADD MANUAL TRANSAXLE OIL
CHECK ENGINE OIL LEVEL
INSPECT AND ADJUST CLUTCH PEDAL SUB-ASSEMBLY
for LHD:Click here
for RHD:Click here
INSPECT FOR FUEL LEAK
INSPECT FOR COOLANT LEAK
INSPECT FOR OIL LEAK
INSPECT FOR EXHAUST GAS LEAK
INSTALL FRONT WHEELS
ADJUST FRONT WHEEL ALIGNMENT
CHECK SPEED SENSOR SIGNAL
w/o VSC:Click here
w/ VSC:Click here