ENGINE ASSEMBLY INSTALLATION

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.

Tip:

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

  1. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY LH

    A206125
    Tip:

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

    1. Install the engine mounting insulator with the 4 bolts.

      95 N*m

      969 kgf*cm

      70 ft.*lbf

  2. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    A206124
    Tip:

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

    1. Install the engine mounting insulator with the 3 bolts.

      95 N*m

      969 kgf*cm

      70 ft.*lbf

    2. A206123

      Install the 2 cooler pipe brackets with the 2 bolts and nut.

      9.8 N*m

      100 kgf*cm

      87 in.*lbf

    3. Connect the cooler pipe clamp.

  3. INSTALL REAR ENGINE MOUNTING INSULATOR

    A206117
    Tip:

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

    1. Install the engine mounting insulator with the 2 bolts and 2 nuts.

      95 N*m

      969 kgf*cm

      70 ft.*lbf

  4. INSTALL FRONT ENGINE MOUNTING INSULATOR

    A206116
    Tip:

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

    1. Install the engine mounting insulator with the 2 bolts.

      95 N*m

      969 kgf*cm

      70 ft.*lbf

  5. INSTALL ENGINE HANGER

    Click here

  6. REMOVE ENGINE STAND

    1. Attach a sling device and hang the engine with a chain block.

    2. Lift the engine and remove it from the engine stand.

  7. INSTALL ENGINE WIRE

    1. Install the engine wire to the engine.

  8. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY (for Manual Transaxle)

    1. clutch release with bearing cylinder assembly (Click here).

  9. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for CVT)

    Click here

  10. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)

    Click here

  11. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)

    Click here

  12. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)

    Click here

  13. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transaxle)

    Click here

  14. INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY

    1. Install the continuously variable transaxle assembly (Click here).

  15. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

    1. Install the manual transaxle assembly (Click here).

  16. INSTALL FLYWHEEL HOUSING SIDE COVER

    Click here

  17. INSTALL STARTER ASSEMBLY

    Click here

  18. TEMPORARILY INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    1. A206115

      Temporarily install the rear engine mounting insulator to the engine mounting bracket with the through bolt.

  19. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    1. Place the engine on an engine lifter.

      Tip:

      Place the engine on wooden blocks or equivalent so that the engine is level.

    2. 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.

    3. A202682

      Temporarily install the front suspension crossmember with the 2 bolts.

    4. A204889

      Temporarily install the member brace rear RH and LH with the 6 bolts.

    5. A214814

      Install the engine mounting insulator LH with the through bolt and nut.

      56 N*m

      571 kgf*cm

      41 ft.*lbf

    6. A158372E01

      Install the engine mounting insulator RH with the bolt and 2 nuts.

      for bolt and nut A

      95 N*m

      969 kgf*cm

      70 ft.*lbf

      for nut B

      52 N*m

      530 kgf*cm

      38 ft.*lbf

    7. A202682

      Tighten the 2 front suspension member bolts.

      137 N*m

      1397 kgf*cm

      101 ft.*lbf

    8. A204889E03

      Tighten the 6 member brace rear bolts.

      for bolt A

      137 N*m

      1397 kgf*cm

      101 ft.*lbf

      for bolt B

      93 N*m

      948 kgf*cm

      69 ft.*lbf

    9. A206126

      Remove the 2 bolts and 2 engine hangers.

    10. Install the air fuel ratio sensor bracket with the bolt. Then connect the air fuel ratio sensor connector.

      60 N*m

      612 kgf*cm

      44 ft.*lbf

  20. INSTALL FRONT CROSSMEMBER SUB-ASSEMBLY

    1. A206114

      Temporarily install the front crossmember with the 4 bolts.

    2. A200734

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

    3. Tighten the 4 front crossmember bolts.

      99 N*m

      1010 kgf*cm

      73 ft.*lbf

    4. Tighten the front engine mounting insulator bolt and nut.

      145 N*m

      1479 kgf*cm

      107 ft.*lbf

  21. TIGHTEN FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    1. A206115

      Tighten the rear engine mounting insulator bolt.

      95 N*m

      969 kgf*cm

      70 ft.*lbf

  22. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH

    1. A200733E02

      Install the reinforcement with the 4 bolts.

      99 N*m

      1010 kgf*cm

      73 ft.*lbf

      Note:

      Tighten the bolts in the order of C, B, D and A.

  23. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH

    1. U122013E02

      Install the reinforcement with the 4 bolts.

      99 N*m

      1010 kgf*cm

      73 ft.*lbf

      Note:

      Tighten the bolts in the order of C, B, D and A.

  24. INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT (for CVT)

    Click here

  25. INSTALL FRONT LOWER ENGINE MOUNTING BRACKET REINFORCEMENT

    1. A214302

      Install the front lower engine mounting bracket reinforcement with the 2 bolts.

      99 N*m

      1010 kgf*cm

      73 ft.*lbf

  26. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  27. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

    Click here

  28. INSTALL FRONT AXLE ASSEMBLY LH

    1. Install the front axle assembly LH (Click here).

  29. INSTALL FRONT AXLE ASSEMBLY RH

    Tip:

    Use the same procedures described for the LH side.

  30. CONNECT FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  31. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tip:

    Use the same procedures described for the LH side.

  32. INSTALL FRONT AXLE SHAFT NUT LH

    Click here

  33. INSTALL FRONT AXLE SHAFT NUT RH

    Tip:

    Use the same procedures described for the LH side.

  34. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  35. INSTALL FRONT FLOOR CENTER BRACE

    Click here

  36. CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click hereClick here

  37. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  38. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  39. CONNECT WIRE HARNESS AND HOSE

    1. A206118

      Connect the vacuum hose.

    2. A200731

      Connect the connector tube hose.

    3. A200730

      Connect the engine wire with the bolt.

      29 N*m

      296 kgf*cm

      21 ft.*lbf

    4. A200729

      Connect the engine wire with the 2 bolt and clamp.

      8.4 N*m

      86 kgf*cm

      74 in.*lbf

    5. Connect the battery current sensor connector.

    6. A209190

      Attach the 2 clamps to install the wire harness.

    7. Install the 2 nuts.

      8.4 N*m

      86 kgf*cm

      74 in.*lbf

    8. Connect the 3 engine room No. 1 junction block connectors.

    9. A350717

      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.

    10. Connect the wire harness clamp.

  40. CONNECT HEATER WATER HOSE

    1. A206121

      Connect the 2 heater water hoses.

  41. CONNECT FUEL TUBE SUB-ASSEMBLY

    1. A209200

      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.

    2. A150566

      Attach the claw to install the No. 1 fuel pipe clamp.

  42. CONNECT NO. 1 RADIATOR HOSE

    1. A209194E04

      Connect the radiator hose to the cylinder head.

      Table 1. Text in Illustration

      *a

      Top
      Tip:

      The direction of the hose clamp is indicated in the illustration.

    2. A209720

      for CVT:

      Connect the No. 1 breather plug to the clamp.

  43. CONNECT CLUTCH HOSE (for Manual Transaxle)

    1. A209972

      Connect the clutch hose and install the clip to the clutch hose.

      Note:

      Install the clip as far as it will go.

    2. Using a 10 mm union nut wrench, connect the clutch hose to the flexible hose tube while holding the clutch hose.

      15 N*m

      155 kgf*cm

      11 ft.*lbf

      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.

  44. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)

    1. C197729

      Connect the control cable assembly with the nut.

      5.0 N*m

      51 kgf*cm

      44 in.*lbf

    2. C201605

      Connect the 2 transmission control cables with 2 new clips.

    3. C201606

      Install the 2 clips.

  45. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for CVT)

    1. C201441

      Connect the transmission control cable support with the bolt.

      5.0 N*m

      51 kgf*cm

      44 in.*lbf

    2. C156645

      Connect the transmission control cable to the bracket with a new clip.

    3. Connect the transmission control cable to the control shaft lever with the nut.

      12 N*m

      122 kgf*cm

      9 ft.*lbf

  46. INSTALL BATTERY CARRIER

    1. A200723

      Install the battery carrier with the 4 bolts.

      19 N*m

      189 kgf*cm

      14 ft.*lbf

    2. A200722

      Install the radiator pipe with the 2 bolts.

      19 N*m

      189 kgf*cm

      14 ft.*lbf

    3. Connect the 2 wire harness clamps.

  47. INSTALL BATTERY TRAY

  48. INSTALL BATTERY

  49. INSTALL BATTERY CLAMP SUB-ASSEMBLY

    1. U123712

      Install the battery clamp with the bolt and nut.

      for bolt

      17 N*m

      169 kgf*cm

      12 ft.*lbf

      for nut

      3.5 N*m

      36 kgf*cm

      31 in.*lbf

    2. Connect the cable to the positive (+) battery terminal.

      5.4 N*m

      55 kgf*cm

      48 in.*lbf

  50. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  51. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  52. CONNECT COMPRESSOR WITH PULLEY ASSEMBLY (w/ Air Conditioning System)

    1. E175927

      Using an E8 "TORX" socket wrench, connect the compressor assembly with pulley with the 2 stud bolts.

      9.8 N*m

      100 kgf*cm

      87 in.*lbf

    2. U123698E01

      Install the 2 bolts and 2 nuts.

      25 N*m

      255 kgf*cm

      18 ft.*lbf

      Tip:

      Tighten the bolts and the nuts in the order shown in the illustration.

    3. Connect the connector.

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

    Click here

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

    Click here

  55. CONNECT NO. 2 RADIATOR HOSE

    1. A209193E01

      Connect the radiator hose to the water inlet.

      Tip:

      The direction of the hose clamp is indicated in the illustration.

  56. INSTALL GENERATOR ASSEMBLY

    Click here

  57. INSTALL V-RIBBED BELT

    Click here

  58. CONNECT RADIATOR RESERVOIR ASSEMBLY

    1. A204819

      Install the grommet to the radiator reservoir.

    2. Connect the radiator reservoir with the 2 bolts.

      5.0 N*m

      51 kgf*cm

      44 in.*lbf

  59. INSTALL RADIATOR ASSEMBLY

    1. Install the radiator (Click here).

  60. INSTALL FRONT BUMPER COVER

    1. Install the front bumper cover (Click here).

  61. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected (Click here).

  62. ADD MANUAL TRANSAXLE OIL

    Click here

  63. INSPECT MANUAL TRANSAXLE OIL

    Click here

  64. ADD CONTINUOUSLY VARIABLE TRANSAXLE FLUID

    1. Add continuously variable transaxle fluid (Click here).

  65. ADD ENGINE COOLANT

    Click here

  66. ADD ENGINE OIL

    Click here

  67. INSPECT FOR FUEL LEAK

    Click here

  68. INSPECT FOR ENGINE COOLANT LEAK

    Click here

  69. INSPECT FOR ENGINE OIL LEAK

    Click here

  70. INSPECT FOR EXHAUST GAS LEAK

    Click here

  71. INSPECT V-RIBBED BELT

    Click here

  72. INSPECT IGNITION TIMING

    Click here

  73. INSPECT ENGINE IDLE SPEED

    Click here

  74. INSPECT CO/HC

    Click here

  75. ADJUST FRONT WHEEL ALIGNMENT

    1. Adjust the front wheel alignment (Click here).

  76. INSTALL NO. 2 ENGINE UNDER COVER

    1. A197474

      Install the under cover with the 4 clips.

  77. INSTALL CENTER NO. 4 ENGINE UNDER COVER

    1. A207261

      Install the under cover with the 2 clips.

  78. INSTALL REAR ENGINE UNDER COVER RH

    Click here

  79. INSTALL REAR ENGINE UNDER COVER LH

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

  80. INSTALL FRONT LOWER BUMPER ABSORBER

    1. A209991

      Install the front lower bumper absorber with the 4 bolts.