2ZR-FE ENGINE MECHANICAL 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.
- NOTICE:
-
for Manual Transaxle:
-
When the manual transaxle assembly is removed, be sure to use a new clutch release with bearing cylinder assembly and a new installation bolts. Removal of the manual transaxle assembly allows the compressed clutch release with bearing cylinder assembly to return to its original position. Dust from the moving section may damage the seal of the clutch release with bearing cylinder assembly, possibly causing clutch fluid leaks.
PROCEDURE
1.INSTALL ENGINE HANGER
2.REMOVE ENGINE FROM ENGINE STAND
Remove the engine assembly from the engine stand.
13405
3.INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)
31250
4.INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)
31210
5.INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)
31210
6.INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transaxle)
31400
7.INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY (for Manual Transaxle)
31407B
8.REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Manual Transaxle)
9.INSPECT CLUTCH PIPE LINE (for Manual Transaxle)
31407B
10.INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Manual Transaxle)
31482
11.INSTALL CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE (for Manual Transaxle)
30300
12.INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)
32101
13.INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for CVT)
30400
14.INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY (for CVT)
82121
15.INSTALL ENGINE WIRE
Install the engine wire to the engine assembly with transaxle.
28100
16.INSTALL STARTER ASSEMBLY
11363A
17.INSTALL FLYWHEEL HOUSING SIDE COVER
| *a | Protruding Portion |
Insert the protruding portion into the end of the cylinder block sub-assembly and fit the claw into the stiffening crankcase assembly.
- NOTICE:
- ·
Make sure that the claw makes a click sound, indicating that it fits tightly.
·Replace the flywheel housing side cover with a new one if the claw does not fit tightly or is deformed.
87245
18.INSTALL HEATER WATER INLET HOSE
Install the heater water inlet hose to the cylinder head sub-assembly and slide the clip to secure it.
16282
19.CONNECT NO. 5 WATER BY-PASS HOSE (for CVT)
12361A
20.TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR
- HINT:
-
Perform this procedure only when replacement of the front engine mounting insulator is necessary.
Temporarily install the front engine mounting insulator to the front engine mounting bracket with the through bolt and nut.
12371A
21.TEMPORARILY INSTALL REAR ENGINE MOUNTING INSULATOR
- HINT:
-
Perform this procedure only when replacement of the rear engine mounting insulator is necessary.
Temporarily install the rear engine mounting insulator to the rear engine mounting bracket with the through bolt.
12372A
22.INSTALL ENGINE MOUNTING INSULATOR LH
- HINT:
-
Perform this procedure only when replacement of the engine mounting insulator LH is necessary.
Install the engine mounting insulator LH with the 4 bolts.
- Torque:
- 52 N*m (530 kgf*cm, 38 ft.*lbf)
12305
23.INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH
- HINT:
-
Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.
Install the engine mounting insulator sub-assembly RH with the 3 bolts.
- Torque:
- 52 N*m (530 kgf*cm, 38 ft.*lbf)
Install the radiator reserve tank assembly with the 3 bolts.
- Torque:
- 7.0 N*m (71 kgf*cm, 62 in.*lbf)
- NOTICE:
-
Tighten the 3 bolts in the order shown in the illustration.
| *a | Hose |
Insert the hose to the radiator reserve tank assembly and install the reserve tank cap sub-assembly.
Engage the clamp to install the reserve hose.
24.INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
Set the engine assembly with transaxle on an engine lifter.
- NOTICE:
-
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.
- NOTICE:
- ·
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.
Install the engine mounting insulator LH with the through bolt and nut.
- Torque:
- 56 N*m (571 kgf*cm, 41 ft.*lbf)
- HINT:
-
When tightening the through bolt, keep the nut from rotating.
Install the engine mounting insulator sub-assembly RH with the bolt and 2 nuts.
- Torque:
- Nut (A) : 95 N*m (969 kgf*cm, 70 ft.*lbf)
- Nut (B) : 52 N*m (530 kgf*cm, 38 ft.*lbf)
- Bolt : 95 N*m (969 kgf*cm, 70 ft.*lbf)
51204A
25.TEMPORARILY INSTALL CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY
51201
26.INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
51204A
27.FULLY INSTALL CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY
12361A
28.FULLY INSTALL FRONT ENGINE MOUNTING INSULATOR
- HINT:
-
Perform this procedure only when replacement of the front engine mounting insulator is necessary.
Fully install the front engine mounting insulator with the nut and through bolt.
- Torque:
- 73 N*m (744 kgf*cm, 54 ft.*lbf)
- HINT:
-
Tighten the through bolt while holding the nut.
12371A
29.FULLY INSTALL REAR ENGINE MOUNTING INSULATOR
- HINT:
-
Perform this procedure only when replacement of the rear engine mounting insulator is necessary.
Fully install the rear engine mounting insulator with the through bolt.
- Torque:
- 95 N*m (969 kgf*cm, 70 ft.*lbf)
30.REMOVE ENGINE HANGER
31.INSTALL WIRE HARNESS CLAMP BRACKET
Install the wire harness clamp bracket with the bolt.
- Torque:
- 39 N*m (398 kgf*cm, 29 ft.*lbf)
Engage the 3 clamps.
32101G
32.INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT (for CVT)
11361J
33.INSTALL FLYWHEEL HOUSING UNDER COVER
Install the flywheel housing under cover to the stiffening crankcase assembly.
34.INSTALL DRIVE SHAFT ASSEMBLY
17410
35.INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Front and Rear Catalyst)
45025D
36.CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY
45260
37.CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY
45259A
38.INSTALL COLUMN HOLE COVER SILENCER SHEET
39.CONNECT WIRE HARNESS
for Manual Transaxle:
Connect the No. 3 engine wire to the manual transaxle assembly with the bolt.
- Torque:
- 12.8 N*m (131 kgf*cm, 9 ft.*lbf)
for CVT:
Connect the No. 3 engine wire to the continuously variable transaxle assembly with the bolt and connect the clamp.
- Torque:
- 12.8 N*m (131 kgf*cm, 9 ft.*lbf)
Engage the 2 claws to connect the wire harness to the engine room relay block and junction block assembly.
Connect the 3 wire harness connectors.
Install the 2 nuts to the engine room relay block and junction block assembly.
- Torque:
- 8.4 N*m (86 kgf*cm, 74 in.*lbf)
Install the No. 1 engine room relay block cover to the engine room relay block and junction block assembly.
Connect the wire harness clamp.
Connect the ECM connector and lower the lever.
88310
40.INSTALL COMPRESSOR ASSEMBLY WITH PULLEY
Using an E8 "TORX" socket wrench, temporarily install the compressor assembly with pulley with the 2 stud bolts.
- Torque:
- 9.8 N*m (100 kgf*cm, 87 in.*lbf)
- HINT:
-
Tighten the 2 stud bolts in the order shown in the illustration to install the compressor assembly with pulley.
|
Bolt |
|
Nut |
Install the compressor assembly with pulley with the 2 bolts and 2 nuts.
- Torque:
- 25 N*m (255 kgf*cm, 18 ft.*lbf)
- HINT:
-
Tighten the 2 bolts and 2 nuts in the order shown in the illustration to install the compressor assembly with pulley.
Engage the clamp.
Connect the connector.
12512C
41.TEMPORARILY INSTALL NO. 2 GENERATOR BRACKET
Temporarily install the No. 2 generator bracket with the bolt.
27020
42.INSTALL GENERATOR ASSEMBLY
Temporarily install the generator assembly with the 2 bolts.
Fully tighten the 3 bolts.
- Torque:
- Bolt (A), (B) : 25 N*m (255 kgf*cm, 18 ft.*lbf)
- Bolt (C) : 43 N*m (438 kgf*cm, 32 ft.*lbf)
- NOTICE:
-
Fully tighten the 3 bolts in the order of (A), (B) and (C).
Connect the generator assembly connector and engage the wire harness clamp.
Connect the wire harness to terminal B with the nut.
- Torque:
- 9.8 N*m (100 kgf*cm, 87 in.*lbf)
Install the terminal cap.
16361A
43.INSTALL V-RIBBED BELT
16361A
44.INSPECT V-RIBBED BELT
23901
45.CONNECT FUEL TUBE SUB-ASSEMBLY
Connect the fuel tube connector and fuel pipe.
- CAUTION:
-
Align the fuel tube connector with the fuel pipe, then push the fuel tube connector in until the retainer makes a "click" sound. If it is difficult to push the fuel tube connector in, apply a small amount of clean engine oil to the tip of the fuel pipe. After connecting, pull the fuel pipe and fuel tube connector to make sure that they are securely connected.
Engage the claw and install the No. 1 fuel pipe clamp.
87245
46.CONNECT HEATER WATER INLET HOSE
87246
47.CONNECT HEATER WATER OUTLET HOSE (for Manual Transaxle)
Connect the heater water outlet hose to the No. 1 water by-pass pipe and slide the clip to secure it.
87246
48.CONNECT HEATER WATER OUTLET HOSE (for CVT)
Connect the heater water outlet hose to the No. 1 water by-pass pipe and slide the clip to secure it.
Connect the heater water outlet hose to the air conditioner unit assembly and slide the clip to secure it.
44774
49.CONNECT UNION TO CONNECTOR TUBE HOSE
Connect the union to connector tube hose to the air tube and slide the clip to secure it.
23826
50.CONNECT NO. 1 FUEL VAPOR FEED HOSE
Connect the No. 1 fuel vapor feed hose to the purge valve (purge VSV) and slide the clip to secure it.
33820B
51.INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)
Install the transmission control cable assembly to the control cable bracket assembly with 2 new clips (A).
Install the transmission control cable assembly to the manual transaxle assembly with the 2 clips (B).
33820B
52.INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for CVT)
Install the transmission control cable assembly to the No. 1 transmission control cable bracket with a new clip.
| *a | P Position |
| *b | N Position |
Turn the lever clockwise until it stops, then turn it counterclockwise 2 notches.
Install the transmission control cable assembly to the control shaft lever with the nut.
- Torque:
- 12 N*m (122 kgf*cm, 9 ft.*lbf)
31418
53.CONNECT CLUTCH HOSE (for Manual Transaxle)
Connect the clutch hose and install a new clip to the clutch hose.
- NOTICE:
-
Install the clip as far as it will go.
Using a 10 mm union nut wrench, connect the clutch hose to the clutch release cylinder to flexible hose tube while holding the clutch hose.
- Torque:
- 15.2 N*m (155 kgf*cm, 11 ft.*lbf)
- NOTICE:
- ·
Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench.
Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>PRECAUTION
·This torque value is effective when the union nut wrench is parallel to the torque wrench.
·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.
54.BLEED CLUTCH LINE (for Manual Transaxle)
16572D
55.CONNECT NO. 2 RADIATOR HOSE
Connect the No. 2 radiator hose to the water inlet and slide the clip to secure it.
16571C
56.CONNECT NO. 1 RADIATOR HOSE
Connect the No. 1 radiator hose to the cylinder head sub-assembly and slide the clip to secure it.
for CVT:
Connect the breather plug hose to the clamp.
74411
57.INSTALL BATTERY CARRIER
Install the battery carrier with the 4 bolts.
- Torque:
- 12.8 N*m (131 kgf*cm, 9 ft.*lbf)
Connect the radiator pipe to the battery carrier with the 2 bolts.
- Torque:
- 8.0 N*m (82 kgf*cm, 71 in.*lbf)
Connect the 2 wire harness clamps to the battery carrier.
28800
58.INSTALL BATTERY
Install the battery clamp bolt to the battery carrier support.
Install the battery tray and battery to the battery carrier.
| *a | Bolt |
| *b | Nut |
Install the battery clamp sub-assembly with the bolt and nut.
- Torque:
- Bolt : 6.5 N*m (66 kgf*cm, 58 in.*lbf)
- Nut : 3.5 N*m (36 kgf*cm, 31 in.*lbf)
Connect the cable to the positive (+) battery terminal with the nut.
- Torque:
- 5.4 N*m (55 kgf*cm, 48 in.*lbf)
59.INSTALL AIR CLEANER CASE SUB-ASSEMBLY
Install the air cleaner case sub-assembly with the 3 bolts.
- Torque:
- 7.0 N*m (71 kgf*cm, 62 in.*lbf)
Connect the wire harness clamp to the air cleaner case sub-assembly.
Install the air cleaner filter element sub-assembly to the air cleaner case sub-assembly.
17705
60.INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE
61.CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Connect the cable to the negative (-) battery terminal with the nut.
- Torque:
- 5.4 N*m (55 kgf*cm, 48 in.*lbf)
- NOTICE:
-
When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
-
Click hereGeneral>INTRODUCTION>REPAIR INSTRUCTION>INITIALIZATION
62.ADD ENGINE OIL
63.ADD MANUAL TRANSAXLE OIL (for Manual Transaxle)
64.ADD ENGINE COOLANT
65.ADD CONTINUOUSLY VARIABLE TRANSAXLE FLUID (for CVT)
66.CHECK ENGINE OIL LEVEL
67.INSPECT SHIFT LEVER POSITION (for CVT)
68.ADJUST SHIFT LEVER POSITION (for CVT)
69.ADJUST SHIFT LEVER POSITION (for Manual Transaxle)
70.INSPECT FOR FUEL LEAK
71.INSPECT FOR COOLANT LEAK
72.INSPECT FOR OIL LEAK
73.INSPECT FOR EXHAUST GAS LEAK
51442C
74.INSTALL ENGINE UNDER COVER LH
Install the engine under cover LH with the 2 bolts, 2 screws and 3 clips.
51441C
75.INSTALL ENGINE UNDER COVER RH
Install the engine under cover RH with the 3 bolts, 2 screws and 3 clips.
76.INSTALL FRONT WHEELS
77.INSPECT IGNITION TIMING
78.INSPECT ENGINE IDLE SPEED
79.INSPECT CO/HC
80.ADJUST FRONT WHEEL ALIGNMENT
11212
81.INSTALL NO. 2 CYLINDER HEAD COVER
Engage the 4 clips to install the No. 2 cylinder head cover.
- NOTICE:
- ·
Be sure to engage the clips securely.
·Do not apply excessive force or hit the No. 2 cylinder head cover to engage the clips. This may cause the No. 2 cylinder head cover to break.
82.CHECK FOR SPEED SENSOR SIGNAL