ДВИГАТЕЛЬ В СБОРЕ УСТАНОВКА

CAUTION / NOTICE / HINT

Note:
  • When the manual transaxle assembly or multi-mode manual transaxle assembly is removed, be sure to use a new clutch release with bearing cylinder and new installation bolts. Removal of the manual transaxle assembly or multi-mode manual transaxle assembly 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.

  • "Injector Compensation" and "Pilot Quantity Learning Values Reset" functions using the GTS.

    Click hereНажмите здесь

PROCEDURE

  1. REMOVE ENGINE FROM ENGINE STAND

    1. Using a chain block and engine sling device, secure the engine assembly.

      Note:
      • Adjust the angle of the sling device carefully to prevent the engine assembly or engine hangers from deforming or becoming damaged.

      • Servicing an engine assembly while it is hanging is dangerous. This can be done only when installing/removing the engine assembly to/from an engine stand.

    2. Remove the engine assembly from the engine stand.

  2. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

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  3. INSTALL FLYWHEEL SUB-ASSEMBLY

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  4. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)

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  5. INSTALL CLUTCH DISC ASSEMBLY (for Multi-Mode Manual Transaxle)

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  6. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)

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  7. INSTALL CLUTCH COVER ASSEMBLY (for Multi-Mode Manual Transaxle)

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

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  9. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Multi-Mode Manual Transaxle)

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  10. INSTALL CRANK POSITION SENSOR

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  11. INSTALL CYLINDER BLOCK SIDE COVER

    1. Install the cylinder block side cover with the bolt and washer plate.

      Момент затяжки
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }
  12. INSTALL EXHAUST MANIFOLD

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  13. TEMPORARILY INSTALL INLET TURBO OIL PIPE SUB-ASSEMBLY

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  14. INSTALL TURBOCHARGER SUB-ASSEMBLY

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  15. INSTALL INLET TURBO OIL PIPE SUB-ASSEMBLY

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  16. INSTALL MANIFOLD STAY

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  17. INSTALL TURBOCHARGER STAY

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  18. INSTALL NO. 2 MANIFOLD SUPPORT BRACKET

    1. Install the No. 2 manifold support bracket with the 2 bolts.

      Момент затяжки
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
  19. INSTALL MANIFOLD SUPPORT BRACKET

    1. Install the manifold support bracket with the 3 bolts.

      Момент затяжки
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
  20. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    1. Install a new gasket to the turbocharger.

    2. Temporarily install the exhaust manifold converter sub-assembly with 3 new nuts and a new bolt.

    3. Fully tighten the 3 nuts first, and then tighten the bolt.

      Момент затяжки
      Nut
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }
      Bolt
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
    4. Engage the 2 harness clamps to the harness bracket.

    5. Engage the 2 harness clamps to the No. 2 timing chain cover.

    6. Connect the 2 exhaust gas temperature sensor connectors.

  21. INSTALL NO. 2 EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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  22. INSTALL NO. 3 MANIFOLD SUPPORT BRACKET

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  23. INSTALL NO. 4 MANIFOLD SUPPORT BRACKET

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  24. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

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  25. INSTALL NO. 2 VACUUM PIPE

    Click hereНажмите здесь

  26. INSTALL NO. 1 TURBO INSULATOR

    1. Install the No. 1 turbo insulator with the 3 bolts.

      Момент затяжки
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }
  27. INSTALL SENSOR BRACKET

    1. Install the sensor bracket with the nut.

      Момент затяжки
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    2. Connect the 2 vacuum transmitting hoses and slide the 2 clips to secure them.

  28. INSTALL HARNESS BRACKET

    1. w/o No. 1 Engine Cover:

      1. Install the 2 harness brackets with the 2 nuts.

        Момент затяжки
        11 N*m  { 112 kgf*cm, 8 ft.*lbf }
    2. w/ No. 1 Engine Cover:

      1. Install the No. 2 engine cover bracket and 2 harness brackets with the 2 nuts.

        Момент затяжки
        11 N*m  { 112 kgf*cm, 8 ft.*lbf }
  29. INSTALL OUTLET HEATER WATER HOSE A

    1. Install the outlet heater water hose A to the outlet outer water sub-assembly and slide the clip to secure it.

  30. INSTALL NO. 2 AIR TUBE

    1. Connect the No. 2 air tube to the diesel throttle body assembly with the hose clamp as shown in the illustration.

      A012JYRC01
      *a View A
      *b LH
      *c Rear
      Момент затяжки
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }
      Note:

      One minute after tightening the hose clamp, check that residual torque is 3.2 N*m (33 kgf*cm, 28 in.*lbf) or more.

    2. Install the No. 2 air tube with the 2 bolts.

      Момент затяжки
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
  31. INSTALL ENGINE WIRE

    1. Install the engine wire to the engine.

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

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  33. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY (for Multi-Mode Manual Transaxle)

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  34. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Manual Transaxle)

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  35. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Multi-Mode Manual Transaxle)

    Click hereНажмите здесь

  36. INSPECT CLUTCH PIPE LINE (for Manual Transaxle)

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  37. INSPECT CLUTCH PIPE LINE (for Multi-Mode Manual Transaxle)

    Click hereНажмите здесь

  38. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Manual Transaxle)

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  39. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Multi-Mode Manual Transaxle)

    Click hereНажмите здесь

  40. INSTALL ACCUMULATOR TO FLEXIBLE HOSE TUBE (for Manual Transaxle)

    Click hereНажмите здесь

  41. INSTALL BLEEDER CLUTCH RELEASE TUBE (for Multi-Mode Manual Transaxle)

    Click hereНажмите здесь

  42. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

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  43. INSTALL MULTI-MODE MANUAL TRANSAXLE ASSEMBLY (for Multi-Mode Manual Transaxle)

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  44. CONNECT WIRE HARNESS (for Manual Transaxle)

  45. CONNECT WIRE HARNESS (for Multi-Mode Manual Transaxle)

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  46. INSTALL STARTER ASSEMBLY (w/o Stop And Start System)

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  47. INSTALL STARTER ASSEMBLY (w/ Stop And Start System)

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  48. INSTALL NO. 1 AIR TUBE

  49. 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 with the 4 bolts.

      Момент затяжки
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }
  50. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    Tip:

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

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

      Момент затяжки
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }
    2. Connect the cooler pipe clamp to the engine mounting insulator sub-assembly RH.

    3. Install the cooler pipe clamp bracket with the bolt.

      Момент затяжки
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    4. Install the radiator reserve tank assembly with the 2 bolts.

      Момент затяжки
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
  51. TEMPORARILY TIGHTEN REAR ENGINE MOUNTING INSULATOR

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

  52. TEMPORARILY TIGHTEN FRONT ENGINE MOUNTING INSULATOR

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

  53. 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.

      ОСТОРОЖНО

      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 through bolt and nut.

      Момент затяжки
      56 N*m  { 571 kgf*cm, 41 ft.*lbf }
      Tip:

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

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

      A012LEGN01
      Момент затяжки
      Nut A
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }
      Nut B
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }
    5. Install the front crossmember sub-assembly with the 4 bolts.

      Момент затяжки
      96 N*m  { 979 kgf*cm, 71 ft.*lbf }
    6. Connect the front engine mounting insulator to the front crossmember sub-assembly with the 2 bolts.

      Момент затяжки
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }
  54. REMOVE ENGINE HANGERS

    1. Remove the 2 bolts and No. 1 engine hanger and No. 2 engine hanger.

  55. INSTALL NO. 1 CLUTCH HOSE (for Manual Transaxle)

    1. Install a new clip to connect the No. 1 clutch hose to the flexible hose bracket.

    2. Using a 10 mm union nut wrench, connect the No. 1 clutch hose to the accumulator to flexible hose tube.

      Момент затяжки
      15.2 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 hereНажмите здесь

  56. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

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  57. INSTALL FRONT SUSPENSION MEMBER REAR BRACE LH

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  58. INSTALL FRONT SUSPENSION MEMBER REAR BRACE RH

    Tip:

    Perform the same procedure as for the LH side.

  59. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH

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  60. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH

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

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  62. INSTALL REAR ENGINE MOUNTING INSULATOR

    1. Install the rear engine mounting insulator with the bolt.

      Момент затяжки
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }
  63. INSTALL FRONT ENGINE MOUNTING INSULATOR

    1. Install the front engine mounting insulator with the through bolt and nut.

      Момент затяжки
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }
      Tip:

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

  64. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

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  65. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

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  66. INSTALL FRONT EXHAUST PIPE ASSEMBLY

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  67. INSTALL FRONT CENTER FLOOR BRACE SUB-ASSEMBLY

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

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  69. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

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  70. INSTALL COLUMN HOLE COVER SILENCER SHEET

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  71. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY (w/ Air Conditioning System)

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

      Момент затяжки
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    2. Install the compressor assembly with pulley with the 2 bolts and 2 nuts.

      A012NF1N01
      Момент затяжки
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      Tip:

      Tighten the bolts and nuts in the order shown in the illustration to install the compressor assembly with pulley.

    3. Connect the connector.

  72. INSTALL V-RIBBED BELT

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  73. INSPECT V-RIBBED BELT

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  74. CONNECT OUTLET HEATER WATER HOSE

    1. Connect the outlet heater water hose to the water by-pass pipe sub-assembly and slide the clip to secure it.

  75. CONNECT INLET HEATER WATER HOSE A (w/o Combustion Type Power Heater)

    1. Connect the inlet heater water hose A to the inlet heater water pipe A and slide the clip to secure it.

  76. CONNECT INLET HEATER WATER HOSE D (w/ Combustion Type Power Heater)

    1. Connect the inlet heater water hose D to the inlet heater water pipe A and slide the clip to secure it.

  77. CONNECT NO. 1 RADIATOR HOSE

    1. Connect the No. 1 radiator hose to the outlet water sub-assembly and slide the clip to secure it.

  78. CONNECT NO. 2 RADIATOR HOSE

    1. Connect the No. 2 radiator hose to the water inlet and slide the clip to secure it.

  79. CONNECT WATER BY-PASS HOSE

    1. Connect the water by-pass hose to the water inlet and slide the clip to secure it.

  80. CONNECT UNION TO CONNECTOR TUBE HOSE

    1. Connect the union to connector tube hose to the cylinder head cover sub-assembly and slide the clip to secure it.

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

    1. Install the transmission control cable assembly to the rear engine mounting bracket with the bolt.

      Момент затяжки
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    2. Install the 2 transmission control cable assemblies to the control cable bracket assembly with 2 new clips.

    3. Install the 2 transmission control cable assemblies to the manual transaxle assembly with the 2 clips.

  82. INSTALL INTERCOOLER AIR HOSE

    1. Install the intercooler air hose with the 2 hose clamps as shown in the illustration.

      A012KTFC01
      *a View A
      *b View B
      *c Upper
      *d Front
      Момент затяжки
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }
      Note:

      One minute after tightening the hose clamps, check that residual torque is 3.2 N*m (33 kgf*cm, 28 in.*lbf) or more.

  83. INSTALL NO. 3 AIR HOSE

    1. Install the No. 3 air hose with the 2 hose clamps as shown in the illustration.

      A012INJC01
      *a View A
      *b View B
      *c LH
      *d Front
      *e Upper
      *f RH
      Момент затяжки
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }
      Note:

      One minute after tightening the hose clamps, check that residual torque is 3.2 N*m (33 kgf*cm, 28 in.*lbf) or more.

  84. INSTALL NO. 2 BATTERY CARRIER

    1. Install the No. 2 battery carrier with the 4 bolts.

      Момент затяжки
      18.5 N*m  { 189 kgf*cm, 14 ft.*lbf }
  85. INSTALL AIR CLEANER BRACKET

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

      Момент затяжки
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }
  86. INSTALL FUEL FILTER SUPPORT

    1. Install the fuel filter support with the 3 bolts.

      Момент затяжки
      17.5 N*m  { 178 kgf*cm, 13 ft.*lbf }
    2. Connect the wire harness clamp to the fuel filter support.

  87. INSTALL GLOW PLUG RELAY ASSEMBLY

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

      Момент затяжки
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }
    2. Connect the wire harness clamp to the fuel filter support.

  88. CONNECT WIRE HARNESS (for Multi-Mode Manual Transaxle)

    1. Connect the 7 connectors.

    2. Connect the 6 wire harness clamps.

  89. CONNECT WIRE HARNESS

    1. Connect the No. 3 engine wire to the manual transaxle assembly with the bolt.

      Момент затяжки
      12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }
    2. Connect the 2 wire harness clamps.

    3. Connect the 4 wire harness connectors and wire harness to the engine room junction block with the 2 claws.

    4. Install the 2 nuts to the engine room relay block and junction block assembly.

      Момент затяжки
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }
    5. Install the No. 1 relay block cover to the engine room relay block and junction block assembly.

    6. Connect the 3 wire harness clamps to the fuel filter support.

    7. Lower the lever to connect the ECM connector.

  90. INSTALL FUEL FILTER ASSEMBLY

    Click hereНажмите здесь

  91. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    1. Install the air cleaner case sub-assembly with the 3 bolts.

      Момент затяжки
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }
    2. Install the air cleaner filter element sub-assembly.

  92. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    1. Install the air cleaner cap sub-assembly with the hose clamp.

    2. Lock the 2 lock clamps.

    3. Connect the wire harness clamp, connector and ventilation hose.

  93. INSTALL BATTERY

    1. Install the battery tray.

    2. Set the battery to the battery tray.

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

      Момент затяжки
      Bolt
      16.5 N*m  { 168 kgf*cm, 12 ft.*lbf }
      Nut
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }
    4. Connect the positive (+) battery terminal.

      Момент затяжки
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }
  94. INSTALL OUTER COWL TOP PANEL (for LHD)

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  95. INSTALL OUTER COWL TOP PANEL (for RHD)

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  96. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for LHD)

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  97. INSTALL NO. 2 HEATER AIR DUCT SPLASH SHIELD SEAL (for RHD)

    Click hereНажмите здесь

  98. INSTALL WATER GUARD PLATE LH (for LHD)

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  99. INSTALL WATER GUARD PLATE LH (for RHD)

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  100. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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  101. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

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

      Момент затяжки
      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 hereНажмите здесь

  102. ADD MANUAL TRANSAXLE OIL (for Manual Transaxle)

    Click hereНажмите здесь

  103. ADD MANUAL TRANSAXLE OIL (for Multi-Mode Manual Transaxle)

    Click hereНажмите здесь

  104. ADD ENGINE OIL

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  105. ADD ENGINE COOLANT

    Click hereНажмите здесь

  106. BLEED CLUTCH LINE (for Manual Transaxle)

    Click hereНажмите здесь

  107. BLEED CLUTCH LINE (for Multi-Mode Manual Transaxle)

    Click hereНажмите здесь

  108. BLEED AIR FROM FUEL SYSTEM

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  109. INSPECT TRANSAXLE OIL LEAK

  110. INSPECT ENGINE OIL LEVEL

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  111. INSPECT FOR COOLANT LEAK

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  112. INSPECT FOR FUEL LEAK

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  113. INSPECT FOR EXHAUST GAS LEAK

  114. INSPECT FOR OIL LEAK

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  115. INSTALL NO. 1 ENGINE COVER (w/ No. 1 Engine Cover)

    1. Engage the 2 hooks to the bracket. Then align the 2 grommets with the 2 pins, and press down on the No. 1 engine cover to attach the pins.

      A012K6VC01
      A012L0C Engage the 2 hooks first.
      A012M0O Engage the 2 grommets next.
  116. INSTALL REAR ENGINE UNDER COVER LH

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

  117. INSTALL REAR ENGINE UNDER COVER RH

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

  118. INSTALL FRONT NO. 3 ENGINE UNDER COVER

    1. Install the front No. 3 engine under cover with the 4 clips.

  119. INSTALL CENTER NO. 4 ENGINE UNDER COVER

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

  120. INSTALL NO. 1 ENGINE UNDER COVER

    1. Install the No. 1 engine under cover with the 2 bolts and 11 clips.

  121. INSTALL FRONT LOWER BUMPER ABSORBER

    1. Install the front lower bumper absorber with the 8 bolts and 4 screws.

  122. INSTALL FRONT WHEELS

    Момент затяжки
    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }
  123. ADJUST FRONT WHEEL ALIGNMENT

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  124. PERFORM INITIALIZATION OF MULTI-MODE MANUAL TRANSAXLE SYSTEM (for Multi-Mode Manual Transaxle)

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  125. PERFORM LEARNING OF MULTI-MODE MANUAL TRANSAXLE SYSTEM (for Multi-Mode Manual Transaxle)

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  126. PERFORM SYNCHRONIZATION POSITION CALIBRATION (for Multi-Mode Manual Transaxle)

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  127. CHECK ABS SPEED SENSOR SIGNAL

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